TS 227 
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Copy 1 



ELECTRIC 





WELDING 




Electric Arc 
Weldin 



THIRD 
EDITION 



PUBLISHED BY 



The Lincoln Electric Co. 

General Offices and Plan I 

Cleveland, Ohio 



1 Hi' oln Motor 

o| ■'-i.iinrj under water, 




New York Citj 
Buffalo 

- 

;ton 



Branch Offn . s at 

Philad) Iphia I hi< ago 

I Detroit ( harlotte, X. C 

( 'olumbus I ■ 11 1 into 

Pittsburgh Monti eal 

M inn< apolis 



Agencies in other principal 



J 



No. HU \ 



Copyright. 1918, by The Lincoln Electric Cr, 









ate \3 wo 

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ELECTRIC ARC WELDING 



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necessary 
of work. 



ELDING in the modern sense of 
the word, covers a number of dis- 
tinct operations. In order to thor- 
oughly understand the subject it is 
to divide welding into two classes 
1st. forge or pressure welding, 2nd, 



autogenous welding'. 

Forge or Pressure Welding 

This term, for want of a better one, is ap- 
plied to welding processes where two pieces 

of metal are heated to the plastic state, then 
forced together by pressure or hammering to 
thoroughly unite them, and complete the weld. 
The familiar example of this is the weld which 
the blacksmith makes by heating two piece- of 
steel or iron in the forge fire, then hammering 
the ends together on his anvil. 

A weld similar to this has been made for some 
time by the use of electricity, where two pieces 
of metal are heated by an electric current, then 
forced together to complete the weld. This 
process is known as butt or spot welding and is 
not the process under discussion in this book. 

Autogenous Welding 

I hi> term is applied to welds winch are made 
by heating metals to such temperature that they 
will fuse together on contact, without any pres- 
sure being applied. The difference between 
autogenous welds and those formerly described 
is mainly the difference in temperature of the 
metal. In the autogenous weld, the metal is 
heated to a state of fluidity and the two pieces 
flow t< igether. 

The use of the autogenous process, however, 

i- not confined to the uniting of two pieces of 
metal. It is used to even a greater extent for 
adding molten metal to other metal pieces or 
parts, thus building them up or filling defects. 

Electric Arc Welding 

Electric Arc Welding is an autogenous 
process. It is used both for joining metal 
parts and also for adding or building metal 
on such parts. In fact, when two pieces 
ire welded together by this process, it is 
done by filling in molten metal, between the 
two pieces, rather than by melting the two 
so that they will join. 



The Electric Arc 

The Electric Arc is formed when electric cur- 
rent is made to jump or arc from one electric 
conductor to another, through the air or some 
other substance, which is not a good conductor 
of electricity. 

\ familiar example of this is the sparking 
which occurs when you touch together two wires 
connected with an ordinary electric door bell 
battery. Another familiar example is the spark 
which passes between two wire terminals on the 
spark plug in the automobile engine and serves 
ti i ignite the gas. 

The arc or spark is produced because the elec- 
tric current is forced through a medium which 
offers great resistance to its passage and hence 
produces heat. 

The object, or the conductor, from which the 
current come 1 - is called the positive electrode, 
the object to which it passes is called the nega- 
tive electrode. 

In arc welding, one wire of an electric circuit 
is attached to or laid upon the steel which is to 
be welded, the other wire is attached to a piece 
of carbon or metal which the welder holds and 
which is called the negative electrode. The cur- 
rent passes or arcs from the piece which is to be 
welded to the electrode which the operator holds. 
In doing so it creates such great heat on the 



i NEGATIVE 




1 ig 1 In aic welding, one wire (the positive) from the weldii g 
apparatus is attached or laid upon the steel which is to be 
welded, the other wire (the negative) is attached to the electrodi 
of carbon or metal which the operator hold? 

1 




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ELECTRIC ARC WELDING 



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piece, thai the portion of the piece around the 
are actually melts and turns into vapor and the 
arc is continuously passing through this vapor. 
The only purpose of the electric arc in weld- 
ing is t" produce the heat fur melting tiie metal. 

Advantages of the Arc 

The electric arc has no mysterious qualities 
which make it especially adapted for welding 
purposes. It is simply the most efficient means 
known for producing welding heat. 

Heat for welding purposes may he supplied 
by the blacksmith's forge lire, by chemical com- 
bination of materials such as thermit or by the 
burning of a gas such as acetylene in the pres- 
ence of oxygen. The heat produced by any of 
these agencies is the same in every particular as 
that produced by the electric arc; the only advan- 
tages of the arc are : 

1st — Production of a Higher Temperature. 
2nd — Convenience in Application. 

3rd — 1 j i\\ ( '.i ist. 

Arc Produces Great Heat 

It is a well known fact that the highest obtain- 
able temperature can lie produced in the electric 
arc. In fact, a temperature can he reached which 
is so high that it cannot lie measured with any 
instruments developed up to the present time. 
The reason an electric arc produces such a high 
temperature is that a large amount of heat is 
produced in a very small area. This in itself 
suggests why the arc is the most efficient means 
of heating metals for welding. 




Fig. J. Photograph of Electric Arc in operation. A large 

amount of heat is produced in a very small area, which makes 

the arc a most efficient means of heating metal-. .<.,." v.v 

THE WELDING ENGINEER.) 



Adaptability of Different Processes 

\s stated above, any of the other methods of 
producing heat will serve for welding work, but 
the difficulty comes in applying them in just the 
way desired. 

The forge lire, for instance. K'lves very well 
where two pieces of metal can lie placed in it, 
heated and then put together as they are on (he 
anvil. This application is. of course, very limited 
In fact, most welding is now done by the addi 
tion of new- metal between the welder) pie 



Thermit Welding 

It was the necessity of adding new metal in 
certain welds which led to the development oi 
the Thermit process of welding. This process 
depends upon the chemical combination of cer 
tain substances which produce a great heat antl 
release molten iron from the combination. Ibis 
process has been wonderfully successful. lis 
advantages can be readily seen in case oi two 
pieces such as a broken locomotive frame, which 
could not be convenienth welded by the forge 
process. By building up a mold around the two 
ends and by pouring in the molten steel gener- 
ated by the Thermit process, new metal could be 
added between the ends and they could be thor- 
oughly united. 

Thermit welding is in fact a casting proce 
and always requires the mold built up around 
the parts to be joined and usually requires pre 
heating of those parts in a charcoal fire or bv 
gas torches. While applicable to quite a range 
-'t repair work, it is not usable in the great field 
of welding, recently developed. 



Oxy Acetylene Weld 



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Oxy-Acetylene Welding has the- advantage 
over both forge welding and thermil welding 
in that this process can be applied to any surface. 
The lie.it is produced by burning acetylene gas 
in oxvgen gas 

1 i •. \ -acetylene has gradually widened the use 
of welding and has made it a common manufac- 
turing process. Even the small garage, the 
blacksmith, anil the jeweler can now use oxy- 
acetylene welding and make great savings over 
fi inner methods. 



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COMPARED WITH OTHER PROCESSES 



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A rail wl 
hi proces 



s and is as solid as a new rail 



The cutting of metals by oxy-acetylene is an- 
other field which has been very widely developed. 
It is used for cutting up scrap, for wrecking steel 



structures, bridges, vessels, etc.. and is without 
any rival as far as speed is concerned in this 
field of work. 

There are many places, however, where even 
acetylene welding cannot be conveniently or suc- 
cessfully applied. In the first place, the heat of 
the acetylene torch is spread over a relatively 
wide area. The greatest heat in the acetylene 
lurch is produced at a point in the inside of the 
flame proper, and in order to get this point down 
to the metal, it is necessary to hold the flame 
very close so that it spreads out over the surface 
of the metal to a considerable degree. 

In welding steel sheets or plates, for instance, 
this causes a great deal of difficulty, owing to 
the buckling and bulging of the sheets, produced 
h\ the wide heating. 

At a recent convention of the Railway Master 
Blacksmiths Association, Joseph Grine, of the 
New York Central Railroad, in discussing this 
point says, "In welding boiler sheets the electric 
process is superior to oxy-acetylene because the 
latter generates too much heat and causes the 
sheets to buckle." 

In another discussion of this same subject at 
a General Foreman's Convention, J. M. Kerwin 
of the Chicago, Rock Island Railroad, says, "We 
use the electric and oxy-acetylene processes, and 
have found that the electric is the best for weld- 
ing patches and cracks, and oxy-acetylene is best 
for cutting." 




*tV?V ~ 



I ig t A rail which has been welded together by the oxy- 
acetylene process but owing to the severe contraction 
of the metal on cooling the rail has broken, 

Still another expression of opinion is given 
b\ the Committee < )n Design, of The American 
Railway .Master Mechanics Association, who 
state, in their report, "From the reports received 
from different roads, they indicate that consider- 
able difficulty is experienced from welding flues 
with oxy-acetylene process, while roads using 
the electric process report very satisfactory 
results," 

These opinions from railway men. are given 
at length, because of their very wide experi- 
ence with welding processes. 



Safety 



Another factor which enters into considera- 
tion of the acetylene process is the matter of 
safety. It is not to be denied that there is a 
great element of danger in the oxy-acetylene 
welding process, particularly where a generat- 
ing plant is used. 

At the meeting of the West Coast Safety En- 
gineers Association, in San Francisco, January. 
1917, R. L. Hemingway, of the Industrial Acci- 
dent Commission of California, called particular 
attention to the possible small amounts of hydro- 
gen existing in the oxygen gas and this commis- 
sion has issued a warning to the public not to 
use oxygen gas, for acetylene welding, unless 
absolutely assured that ii does not contain more 
than 2' i of hydrogen gas. 

These matters are not brought up in any effort 
to discredit acetylene welding, but because they 
are necessary to any intelligent practical con- 
sideration of the subject. 



'; I ' t. mi: . 




II! 



ELECTRIC ARC WELDING 



Arc Welding is Convenient and 
Safe 

\"o\v let us compare arc welding with the 
other processes, as in convenience and safety. 

Arc welding can be applied anywhere that 
electric current is available or can be generated, 
and where an electric cable can be carried. It 




i all forms ol wi 



can be used inside boilers and fire boxes, in ship 
lipids, perhaps the most inaccessible location that 
can be imagined, Owing to the action of the 
arc. seams, etc., can be welded over tic head oi 
the operator with no great difficulty. 

Electric arc welding can be used for joining 
parts, for building in molten metal or fur build 
ing up. 

With apparatus of the proper design, arc well- 
ing is the simplest welding process m exist 
It requires a minimum of preparation. Preheat- 
ing' "i the part- to he welded is necessar) only 
in the case of high carbon steel or cast iron. 
The heat is applied on a \cr\ small area, so that 
there is no buckling or undue expansion of 
sheets or plates. 

The steel for filling in or building on is pro- 
duced bv the melting of the electrode which the 
operator holds in his right hand, thus the left 
hand is always free for placing of parts and 
adjustments, making the process practically con- 
tinuous'. 



There is absolutely no danger in the operation 
of properlv constructed electric arc welding 
apparatus. 

The voltage employed is very low, in fact 
lower than that of a residence lighting system, 
and cannot by any possibility injure the operator. 

Comparative Cost of Arc Welding 
.Did Acetylene Welding 

It is not necessarx to discuss the forge weld- 
ing process or thermit welding, as to cost. In 
each of these processes the o >st of preparing the 
parts for welding is vcr\ high and neither "i the 
processes are usable except in certain limited 
applications. 

'|'],e 1 1 nest i, ,n of cost res. ih es itself int" a com- 
parison of electric arc welding with oxy-acety- 
lene. The simple fact that the electric arc pro- 
duces a higher temperature than the acetylene 
gives the arc a decided advantage. 

Perhaps the best comparison can he obtained 
b\ giving actual figures on such operations. One 
large manufacturer of tanks and similar prod- 
nets, employs both oxy-acetylene and are proi 
esses and has made careful comparisons oi o I 
The report from one particular test made on 
identically the same work is summarized below 
and shows conclusively that the arc will weld 
this tank at less than one-half the cosl of the 
acety lene pn icess. 

Objects Welded —Six 215 gallon tanks. •■." 
shell, ;," heads with one 3" and _'" and l 1 :" 
standard o mplings. 



-FEET WELPEP 
LOHG SEAM 6.69" EOUOL TO 31.SFT 
CI(?CUL(!R SEAM XZ + VW • " 9S>. 
COUPLING S 6 « 2" 0" » •• 12. 

t-ii-iPE coupling. TOTAL FOR SIX TANKS 110 .5 FT 

J-3 PlPf COUPLING, £-2 PIPE COUPL'MG 




215 dflLLOrl TflMK 

■1' SHELL\ j£ HEAPS 



I ig ' Gallon Tank comparative cost test was made. 



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COMPARATIVE COSTS 



ii 




Acetylene If elding 

Welding Outfit: — Stationary Generator, No. 
2, Welding torch number 7 and 8 tip. 

Time of welding, 18' 4 hrs. Ca 30c per hr $ 578 

< Ixygen consumed. 371 cu. ft. at .0135c 5.0085 

Acetylene consumed, 325 cu. ft. at .008c cu. ft - 2.60 
Filling material. 15^ lbs. at 12c per 11. 1.89 

Total cost for 6 tanks $15.2785 

Cost of welding I tank 2.S-4 

Arc Welding 

Welding Outfit — Transportable type for one operator, 
manufactured by The Lincoln Electric Co., Cleveland. 

Ohio. 

Time of welding. 14 hrs. (8 30c per hr $4.20 

Kilowatts consumed. 60 kilowatts (S 2c per 1.20 

Filling rod used. 27 lbs. (S 7 3-10c 1.97 

Total cost for 6 tanks §7.37 

Cost of welding I tank / .23 

The Railway Electrical Engineers Association 
have made a very careful investigation of this 
subject, since the railroads use welding to an 
enormous extent. Their committee on this sub- 
ject reporting at their 1916 Convention, states, 
"Three kilowatt hours of electric energy (cosl 
6 cents) will produce the same amount of heat 
as mav be produced by approximately 6-6,. 10 
cubic feet of acetylene (cost 1 1 y _■ cents) and 
7-5 10 cubic feet of oxygen (cost 15 cents)." 

The parentheses in the above quotation are 
our own and they indicate the normal prices of 
electric current, acetylene and oxygen. It will 
he seen that 6 cents expended in electric energy 
will do the same amount of welding work as 
26 J / 2 cents spent for oxy-acetylene gas, on the 
assumption that the two processes make equally 
effective use of the heat produced. 

This assumption, however, is not in accord- 
ance with the facts, since it can be shown that 
nil any welding operation, the heat produced by 
the electric arc will be at least three times as 
effective; that is, three times as much welding 
can be accomplished with it as can be done by 
the same amount of heat produced by the oxy- 
acetvlene torch. 




I'ig. 7 tias tank mail.' by the Boom Boiler & Welder Co., 
Cleveland This tank has been made both by arc welding and 
bj acetylene welding. The an welding cost '4 to '. .0 mm I. 
as gas welding. The tank is tested at 150 lbs water pressure 




Fig, 8. A radiator welded by the Standard 1 Ml Co., of Indiana 
Comparative costs by Acetylene and Arc Welding were as follows: 

Cost af Acetylene Weld on Radiators 



40 cu. ft. acetylene at 


$ Jit 


$ .4n 


48 cu. ft. oxygen at 


.016 


.768 


2 hrs. time at 


.45 


.90 



Cost Of Sil'liC 

16.6 K. W. H. at 

2 hrs. time at 



$2,068 



with Electric Weld 

.006 per K. W. II. $ .10 
45 per hr. .90 

$1.00 







ELECTRIC ARC WELDING 



Minn nun 






mi .11,1 n i: 



The same committee submitted to the Conven- 
tion, a chart which i- reproduced on page 7, 
showing the oust comparison between gas and 
electric welding", based on the amount of beat 
produced. 

The table on page 6 shows a complete com- 
parison of cost~ compiled by an engineer, who 

has made a special subject of welding, in a mini 
bet" of different fields 

Gordon Fox, writing in the Railway Mechani- 
cal Engineer, November. 1916, sums the whole 
matter up as f< >lli i\vs : 

"For work "ii brass, bronze or aluminum the 
oxy-acetylene flame has no competition. 1 he 
main point of superiority of the arc method is 
its economy, as tin- electric arc produces the 
necessary heat at a much lower cost than does 
the oxy-acetylene flame. In its field, the arc 
also produces results as good, if ii"t better, than 
can be obtained with gas, i. e., flue welding, < i 
To avoid excessive cost, predicating is almost 
ahvavs necessary in gas welding, but may often 
be dispensed with in arc welding. The cost oi 
electric power for a welding job will only be 
from 15 to 25 per cent of the cost of oxygen and 
acetylene for the same job." 



It will be seen from a careful stud) "t the 
above authorities that arc welding is beyond 
question far more economical than acetylene 
welding, where a large amount of work is to 
he done. 

In a -mall shop, such as a garage or black- 
mail, or in any place where welding i- onl\ done 
at long intervals, such as repair work in ma- 
chine shops, the acetylene process lias the advan- 
tage because of the low firs! cost of equipment. 

Wherever there is work enough in a com- 
mercial welding shop to keep two or three opera- 
tors continually busy, arc welding will show a 
saving great enough to pa\ for the additional 
cost of equipment in a ver\ short time. 

In ,! niaiin fai 1 in ing plain w here tile w i irk 
can be done with the arc, it will sometimes pa\ 
to install an arc welder when there is only 
enough work to keep an operator bus) with the 
gas torch five In airs per day. 

While some -aving may be made in acetylene 
welding, by generating the acetylene at the plant. 

a g 1 generator for this purpose will cost quite 

as much as arc welding apparatus, and acetylene 
welding will still cost twice as much as the arc 
process. 



TABLE OF COMPARATIVE WELDING COSTS— METAL SHEETS AND PLATES 
BASED ON FIGURES IN YEAR 1916 



Acetylene Welding 



Arc Welding 



•111' 

No 


Thickness 

of Metal 


Cu it p, 


hour 





i . i 


T 
P 


il.il COSl 


l "ost per 
Welded ft 




K W 


e 


Welded 


Total 


it welded 


1 




3.21 


3.65 


all 


.15 




.58 


.01') 














_> 




4.84 


: 5li 


2? 


.19 




64 


1 






.06 


25 


T : 


1124 


3 


1 


8.14 


9 28 


.'n 


33 




78 




, - 


5 iis 


or, 


20 


: i 


.025 


4 




12.511 


14 27 


15 


5li 




'i : , 


063 


Sll 




in 


1 ; 


.51 


. 1 134 


5 


1 .. 


17.81 


21.32 


') 


1 




1. is 


.151 


90 




.07 


111 


.52 


052 


6 


' . 


24.97 


28.46 


ii 


1 INI 




1 45 




llll 


4 15 


1 l,V 




. 55 


067 


7 




53.24 


57.90 


s 


1 55 




1 7s 




110 


4.15 






55 


067 


8 


; s 


41.'' 1 ' 


47.87 


4 


1 (k'S 




2 15 


. 555 


12ii 


4 ',4 


.11'' 


: 


54 


His 


9 


'-■ 


57.85 




5 


2.51 




2 76 


o 


15n 




.12 




. 57 


19 


in 


s s 


82.50 


"4 H5 


) 


iO 






1 .870 


15ii 


5 . 75 


.12 


5 


57 





Above data based en following 
Call irific \ alue i if 



COSl 



Acetylene 2c per cu. ft. Cb 
Power 2i pi i K. \V. Hr Lab , r Hr. 

:etylene is 1555 B. T. U. per cu. ft. One K. \\\ Hr, i? equivalent to 5415 B. T. U. 



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CARBON AxND METAL ELECTRODES 



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Acetylene Gas. If per cu. ft. 
Oxygen Qas 24 - » « 
Power, liper KWH from 
75 Voll Line 






/ 


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3 BO 




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7/6 


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500 






















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to ZO 30 40 SO 60 70 &0 90 fOO 

Heaf units Per Hour- B.T.U. +/0OO. 

Fig. 9 Curves showing the comparison between cost of gas and 
electric welding based on the number of heat units per hour. 
Taken from Association of Railwaj Electrical Engineers Report. 



- Carbon and Metal Electrode 

In electric arc welding there are two distinct 
processes. In one, the electrode manipulated 
by the operator is a carbon pencil, from '4 inch 
to l'j inch in diameter, and 6 to 12 inches in 
length, pointed to bring the arc into as small 
a space as possible. The carbon arc is simply 
used to supply the heat and the operator feeds 
in the filling metal from a melt bar held in his 
left hand. 

In the other process, known as the metal elec- 
trode process, the electrode is a metal wire of 
comparatively small diameter and this wire grad- 
ually melts itself away, furnishing the metal for 
tilling. 

The carbon electrode process is only used 
where it is desired to do fast melting and to 



heat over a large area. Such work would be 
found in the filling in of large holes in castings, 
The carbon arc demands from 300 to 600 am- 
peres of current and the beat produced is 50 
intense and the glare so blinding that the opera- 
tor must wear gauntlet gloves and a shield com- 
pletely covering the head and shoulders. 

The metal electrode process is used for 90 per 
cent of all welding work. The heat is only 
spread over a very small area, enabling the 
operator to deposit the metal very accurately on 
edges of sheets, plates, etc. This process re- 
quires only 50 to 175 amperes current and since 
the heat is not so intense the head and shoulder 




Fig. 10, Cart. mi Electrode Welding. The operator holds the 

carl electrode with the right hand and feeds the filling metal 

into the weld from a rod held in his left hand. 




Fig. 11. Metal Electrode Welding, The electrode in tins i lsi 
a metal wire of small diameter and this wire gradually 
itself away, furnishing metal for the weld 



li 



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ELECTRIC ARC WELDING 






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shield is not necessary but a fact- shield with 
colored glasses can be worn instead. 

The question of which process to use is de- 
termined entirely by the work to be done and 
a good idea can be obtained by studying the 
various applications of welding presented later 
in this b< » ik. 

Operation of Electric Arc 

Generally speaking, no greater skill is required 
in the operation of the electric arc than would 
be necessary in any other modern manufacturing 
process. An intelligent man can learn to do 
simple welding work in from two days to . 
week's time, depending on the nature of the 
work. Great skill is of course acquired by prac- 
tice. Electrical knowledge is not necessary. 
The apparatus now available for this use prac- 
tically never needs attention and can be operated 
with less care than almost any machine tool used 
in the modern sin >p. 




Fig I This woman h.is learned to use the electric arc weldci 
■ 55 than .1 week and lias replaced the man who formerly did 
this work, allowing him to enter military service. 



Characteristics of the If eld 

h should never be overlooked in considering 
welding that the new metal in a weld is simply 
metal which has been melted and cm. led again, 
and il partakes of the properties of a cast metal 
rather than of rolled or wrought metal 

For instance, in welding two pieces oi boiler 
plate the weld will have just as great tensile 
strength as the original plate, but being cast steel 
it cannot have the ductility which rolled steel 
stock possesses. The cast steel in the weld may 
have tin- properties oi ingol steel so tar as duc- 
tility is concerned. 

ii used i" be common opinion thai a weld 
could not be made which could be readily ma- 
chined, but this mistaken impression lias long 
since been corrected. The weld, when properly 
made, can be machined as readily as any steel 
casting i >r flange steel. 

Welding has been used to such an extent for 
ring breakage and defects that unless thor- 
oughly po-ted, the e man is apt to look 
upon it as a "patching" or "doctoring" process, 
whereas it is accepted in the most advanced engi- 
neering practice and is used to a wonderful ex- 
tent in automobile, locomotive and other con 
sti action of the highest charai ter. 




'''s' 13. An Arc V . as , ... , i This 
' ,! " u ~ ■"' armatun been worn in service, then 
l,ullt «P b J welding on new teel I - i g turned 



CHARACTERISTICS OF WELDING 



llll ' 



I 




Applications of Arc Welding 

It is beyond the power of any one man and certainly beyond the limits 
of this book to give an adequate idea of the applications of electric arc 
welding. 

Within the last few years the apparatus for this purpose has been 
highly perfected. Such enormous strides have been made in its applica- 
tion and use, that it is difficult to see any limits to its adaptability. 

The following pages are intended as an outline of work which has 
actually been done. To any one interested in applying the process to his 
product, the best advice is to consult an expert in this line of work as to 
the feasibility of the particular job he has in mind. 



What Metals Can be Welded 

Electric arc welding is most successful on 
Steel, iron and the various alloys of these metals. 
It has been applied with great success to the 
welding" of cast iron in various forms but cannot, 
because of the great heat produced, be used on 
cast iron where the sections are thinner than 
: inch. 

Ilie arc is not practicable for welding alumi- 
num. Acetylene is the best process thus far dis- 
covered for this work. 

General Rule 

Wherever steel or iron parts are to be joined 
or breakage and wear of such parts repaired, 
there should at least be a careful investigation 
of the possibilities of arc welding. It can be 
stated with certainty that any job of this char- 
acter which can be done with acetylene can be 
done at lower cost and at greater speed with 
the electric arc. 

While the following pages do not represent 
one per cent of the total possible applications of 
this process, they will serve as suggestions t<> 
manufacturers and others interested in the high 
development of iron and steel fabrication. 




Fig. 14. Electric Arc Welder used by tin- Standard Oil Co., 

to caulk leaks in vapur lines an, I Mil stills, Tin- vapors are very 

inflammable and every joint must be absolutely tight, hence 

welding is used in addition to riveting. (See Fig. 73.) 



k 



in: ■ .-...: ,! ,.■ ' ,. 



UNI I 



■ 



ELECTRIC ARC WELDING 



■n in, 



Steel Foundries 




I jg 15 [-"illing blow holi in ;i casl st< el tnotoi 11 ui U ■■■ heel. These ' 

strain, wen approved foi use in militar) m '"i trucks when ciefeel wen repaired with the electi 




I i- if. r.lmv holes in steel casting whii epaired in . 

f< \\ minutes h\ i li welding. 




Fig, 17. Tin- lol -i castings showed defects which would have 
delayed delivi i customer one oi two days. Willi i 

Wcldei thej perfect an. I delivered on scheduh tinu 



I he first large cunimercial 1 1 - • oi an weld- 
ing was in the repairing of defects in steel cast 
nigs Tin- manufacture of these castings i- a 
must difficult process owing t<> the high melting 
point and ilif difficulties of pouring molten steel 

Even in pouring the straight steel ingot, it 
i- difficult enough in secure a sound ingot, owing 
in the gases which air given off, causing blow 
holes in the castings. In tin- more complicated 
shapes in which steel '-a-tmu- arc made, it is 
almost impossible to produce a large run of 
iiiL's without sand spots, caused 1>\ the washing 
awa\ nf parts of the mold, or blow holes caused 
by tin- formation nf ^.'ims. Even where the cast- 
ing is otherwise sound, the excessive shrinkage 
i a' tin- steel frequently causes shrinkage cracks 
to appear or causes undue -tram- to be set up 
in the inside of tin- casting itself. A few years 
ago, automobile construction and refinement in 
agricultural implements and other lines greatly 
increased the demand fur steel casting? I . 
numbers of these castings had small defects 
which did not serioush affect their strength, but 
did impair their appearance. The high cosl 
tin- steel castings and the percentage nf waste 



in 



Illll mum niii.; 



miillillliliijiiiimini' ■ I n imi >. mil 



STEEL FOUNDRIES 



led sonic one to hit upon the electric arc as a 
method of repairing these minor defects. They 
reproduced on a small scale the conditions of the 
electric furnace. It was a perfectly logical run- 
elusion that if steel was melted and poured into 
these defects, the defect would he filled with 
cast steel which would be in every way as good 
as the rest of the casting. 

It was not long before the steel foundry-man 
and all users of steel castings became convinced 
of the merits of this process and castings with 
defects repaired in this manner were accepted 
and used without question, as being in every way 
equal to castings which came perfect from the 
mold. 

Better Deliveries 

This use of the electric arc has not only saved 
great sums of money for the steel foundryman, 
but it has greatly improved deliveries of eastings. 
Formerly, the foundryman could not absolutely 
assure his customer that all of any given days' 
production could be counted upon, but with the 
introduction of the electric are, defects are quick- 
ly repaired and delivery schedules can thus be 
accurate!)' maintained. 

Manufacturers who use steel castings fre- 
quently find it advisable to install their own weld- 
ing outfits thus saving the return of the castings 
to the foundry when small defects are discovered 

in machining or in testing. 

In face of the traffic conditions recently exist- 
ing one firm found it very profitable to install 
the arc welder rather than to ship the castings 
hack to the foundry thirty miles away. 



The use of the arc welder saved 
and time. 



both 



money 



Less Skilled Liib 



or 



Electric arc welding has also relieved the labor 
situation in the foundry. It has become harder 
and harder to secure skilled labor, especially 
molders, for this work. The supply of such men 
di es not keep 'pace with the increase in demand. 

Under former conditions it was useless to put 
an apprentice on such work, as the material he 
would spoil and the floor space he would occupy 
would lose for the foundryman far more than 
it would gain for him. 




B( fo 



\Il.r 



Fig. is. Steel Pulley 1. ' . t ■- 1 1 1 l ljl on which .1 defective boss has been 

repaired by building up with the are welder. A shrinkage crack 

in the rim has also been repaired h\ arc welding. 




Before 



\it 



er 



Fig 19. Large Steel Geai showing shrinkagt 
would have made it necessary to scrap the casting 

In 1 11 f'H .in welding. 



ck ulne 

iad it m 










Defi 



Mi. 

Wl llll 



] ig 20 Ali't-H Bracket Steel Casting from which a riser has 

been cut with the arc welder This cut was through about 3 

inches of steel and took approximately six minutes. 



11 




iiiimiiiliiiniiilliiiiiiiniiimiiiiiiimiiiimiiiiiii i i h i i him nm mi i in minim miiiiiiiiiiiiiiiiimiiiiiiiiiiiiiiiiiiiimi 

ELECTRIC ARC WELDING 



IIIIIMI M 



I n An Wi M I 

I'oundi ; Co., i !hii ago, 111 



With the electric arc, however, the mistake? 
which the heginners make cm in nine cases out 
of ten he remedied and one or two welders can 
take care of the work for a fairly large foundry, 
even where the proportion of cheap help is quite 
high. 

\s has been stated, arc welding is not in am 
sense a "patching" or "doctoring" process. 1 he 
defective parts of the casting are melted and i 

i in solid steel. These welded parts are just 
as strong a- any other portion of the casting 
ami when the work is carefulh done the) ma 
chine and finish perfectly. Mam steel foundries 
where welders are in use arrange to take hack 
castings which have shown defects in the machine 
-In i]i ami alter welding them return them to the 
custi uner. 



Operation <>f Arc 




M i- eas\ t<> prevent the usual troubli 
to tin- so called "chilled" or hard weld. I>\ apply- 
ing the arc for some minutes to the pari m 1"' 
welded, thus thoroughly preheating the surround 
ing metal. When the weld i^ made the whole 
mass then cools off slowly and the sudden chill 
ing of the new metal is avoided. 

The ,nc can he used i"i' pre heating the cast 
ings m exacth the same manner as the 
acetylene flame is used. 

Sometimes a slag covering i- provided to ex- 
clude the air from the molten metal and thus 
prevent the presence of oxide in the finished 
weld. This i^ only necessan in special ca i 

With these simple precautions anj steel foun- 
dry can use the arc welder successfull} and 
many castings that would otherwise be a dead 
loss 




William W'l 




Co . Easton, I'.i 



23A. Defective pulley casting Re] 

I. iiu ciln Arc Welder saved 5 I" 2 1 inute? 



STEEL FOUNDRIES 



iiiiniiiiiiiiiniiim muni ' i ' i ni: « m " iiitiiiiiiiiiini! 



II IIIIIIIIIIIIIIIMIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIlllllllllll 



iiiiiiii n 




Welds Easily Machined 

The weld in the casting is as soft and is as 
readily machined as any other portion of the 
work. The blow holes or shrinkage cracks, sand 
holes, etc., are first pre-heated by playing the 
arc over the surface, holding the casting in such 
a position that sand and foreign matter will he 
Hushed out. This work is done with the carbon 
electrode. The filling material can be obtained 
from steel wire, especially made for the purpose 
or even from steel scraps or bars <>| suitable 
analysis. Burning out sand spots with the oxy- 
acetylene flame is impractical, because the re- 
flected heat burns off the end of the tip. \\ here 
the oxy-acetylene flame is used, it is necessary to 
chip out sand spots with a pneumatic tool, which 
makes the cost of the operation very high. 

Electric Steel Foundry 

The electric steel foundry can use electric 
arc welding to particular advantage. In these 
castings, the metal electrode process will ordi- 
narily be best suited. The defects can be chipped 
out with a pneumatic hammer and since they 
are nut large, can lie readily repaired with the 
metal electrode. 




I ig, 24. Lincoln Arc Weldei 400 ampere capacity installed in 

Hi,, plant of 'I'lu Standard Steel Castings Co., Cleveland. O. 

I ti tin background i^ space i ■ i ■ ■ ^ ni- 'I foi tl stall •' of 

another welder 



Sizes of Welders 

The size of welder adapted for certain work is 
a matter which should he passed on by the manu- 
facturer of the apparatus. However, certain 
general sizes can be suggested. 

For steel foundries using the metal electrode 
or very light carbon electrodes on small work, 
a welder supplying 20(1 amperes will usually be 
sufficient. This is an ideal size for the electric 
steel foundries. 

For the foundry making castings up to Unto 
pounds, a welder should be used which has a 300 
ampere capacity. For the very large foundry, 
where large work is produced a 400 ampere 
welder is the ideal size, and is arranged so that 
two or more machines can he connected together 
in parallel, thus giving the current for heavy 
carbon electrode cutting. 



Equipment 



See pages 50-54 for illustration 
suitable for steel foundries. 



of apparatus 




Fig. 



Filling in a lil 



Electrodt 



n ,i -till casting bj tin i 
process 



13 




. IIIIIIIIIKII Ill 

ELECTRIC ARC WELDING 



■ ... . . 



in 



■ I = : 1 1 1 - - - . 1 1 ! . =" : : ■ ■ 



iiiiniiiiiiiiiniimiiiiiii 



Grey Iron and Malleable Foundries 




I i -• ' .. '■ .. ' ' I part ol Hi. 

. . I i nut by u rM 

I ical 







The use of electric arc welding has recentl) 
been extended to grey iron and malleable cast- 
ings to a very large extent. There are man\ 
minor defects in both grey iron and malleable 
castings, which mar the appearance of the cast- 
ing Inn do not seriously affeel its strength. 
I he-e can be repaired and Idled to good advan- 
tage with the arc welder, unless the casting? are 
very thin. 

The . Imcrican Machinist says: "The arc elec- 
tric welder is used on malleable iron castings for 
two purposes: First, for adding material that 
has been either swept away in the mold or is lack- 
ing because of a mistake in the design, and sec- 
ond, in save castings that have blow holes or 
sand holes. It" metal could not be added to make 
a sound repair, castings would often have to be 
scrapped : a i rK patched casting would be con- 
demned for appearance sake, and one with un 
sound joints would be weak and tend to frac 
lure." 

The difficult} encountered in welding cast iron 
arises from the expansion and contraction of the 
local area heated by the arc and the tendency 
of the wel<l to become hard when the casting has 
ed. With the proper equipmenl for pre 
heating furnaces and with skilled operators it is 
probable that 809! of all grey iron castings can 
he welded using the carbon electrode process. 
The metal electrode process i- very difficult to 
use on cast iron because of the extremely small 
heated by the an Tins, of course, would 
be .hi advantage in welding any other material 
than cast iron. 

The Welding Engineer says in a recent article: 
"Welding cast iron with the electric arc process 
will become a very common practice within a 
few years." 

The grey iron or malleable foundry contem- 
plating the use of arc welding should call a 
welding engineer and consult with him as to the 
possibilities of the process on the particular class 

• k which tllev de-ire to di i. 



- shown 11. I ,11, -i welding II.. 

.... .1 nil j 

ining. 

:/./( H1.X1ST) 



',' 



>- 



Malleable Iron Switch stand showing .i defe* i which 
i. nt t.i reject it for appearance sake, but which was 
readilj remedied by \rc Welding. 



14 



I ■■: 



: ■■ ii ii 111 Nimimniii 



III! .iMlllllimliUllllllliiHI 



ELECTRIC ARC WELDING 



i :i 



■i"'. 'Mi, .in iiiiiiiiii ■ -..i . nun .1 iiiiiiiii 



ii ■ 'i 




Railroad Shops 




Welding 



] motive side frame using a portable Lincoln Arc Welder. The same week that this photo 

was taken $6,000 were saved through arc welding done on tins welder. 



Xext to the steel foundry, the railroad has 
probably made the widest use of electric are 
welding. 

The use of welding in the railroad shop has 
become of especial importance since the United 
States entered the World War. 

It is impossible to build locomotives fast 
enough to meet the traffic demands and the only 
possible solution to the problem is to make re- 
pairs more quickly and to keep more engines in 
service. 

Mr. E. Wanamaker, Electrical Engineer of 
the Rock Island R. R.. recently in a very inter- 
esting article in the Railway Electrical Engineer. 
among other things, says: "Our figures show 
that the saving effected by the electric arc weld- 
ing system is being made at the rate of approxi- 
mated $200,000 a year with our present equip- 
ment. This figure includes a direct saving as 
compared with other methods of about $13(3.000. 
There is also a saving arising from the fact that 
we keep engines in service a greater portion 
of the time, which makes up the balance of the 



$200,000. Our figures show that we are saving 
about 1400 engine days per year. We have ob- 
tained, in other words, service of four additional 
engines without any expenditure beyond that 
required U> install the welding system. 

"The net returns secured mi the electric weld- 
ing investment amounts t>> approximately 500% 
per vear. These figures show that the installa- 
tion of the electric welding system on the Rock 
Island Lines has been a very profitable invest- 
ment. 

"There is still a totally unexplored field in the 
maintenance of freight and passenger cars, which 
promises to eclipse in importance maintenance of 
motive power. The present indications are very 
strong that when we go fully into the electric 
welding process in the fire box, boiler, locomo- 
tive, machinery, steel tanks, car work, track 
work, etc.. we can well use 150 units and effect 
a net saving of approximately one million dol- 
lars a year. 

"We could with this equipment in operation 
show a saving of around 7000 engine days a year 



15 




'. iiniiii ii 111 mm... mill! i i mm n iilillllllllllllllillilllllllllimnil 

ELECTRIC ARC WELDING 






iiiiiiiiiimiiiiiniiiniiiiiim in mi iii'ii urn 



I : 1 1. 1- repaii .il by elect mi 

■ t these rods w ere badl \ \v ■ : : ,1 was 

iitult m by the use "t tin .hi nn,- of them I: 
the othei shows onlj tin rough weld, b itty was the 

in t hat it is difficult to t- 11 w hich is w 




I iiln urn i epaii ed 1>\ Klectrii \ti W 
Tin- lii de hi tin- fulci inn \\ as had j ■ 

pei band oi ferrule of the right size in the hob and bu 
up around ii the ferrule could hi knocked out aftei thi 
ing u a: a pei fectly sni hob . 

which needed no machining 




I ii 1 13. An eccentric sheave repaired !>v electrii welding show- 
ing how it is possible to wild both malleable and grey iron. The 
l -.i\ in the driving wheel shaft lias also been built up and 

milled .nit, -.hums tin scrapping of tin- entire shaft 



which means that we would be able to secuu 
from our present engines a mileage that will 
equal that which could otherwise only be secured 
b} the purchase of 23 additional engines." 

The figures on the work dune mi the Rod 
Island R. R. are reproduced on page 24 and are 
worthy of very careful study. 

Even day that the locomotive is laid up in 
the repair shop, means a loss of a large sum of 
money for tin- road. Tbe use of th< electrii 
arc has made it possible t<> repair a great num- 
ber nf cases hi' breakage and wear without dis- 
mantling the locomotive, thus putting it back into 
service within a day or two. instead of keeping 
it in tin- shop a week or ten days. 

The importance of reclaiming broken and 
worn parts of rolling stock lias become a sub- 
ject ol vital importance with the railroads in 
the past few years. Greater attention than evei 
before has been given to these smaller economies 
with a view to building up the earning capacity 
of the road. In fact, the motive power depart 
meiit has assumed a very large part in putting 
the roads on a dividend paying basis. 

The chief uses of the electric arc in the rad- 
ii .id shi >p are : 

1. Welding flues in back flue-sheet. 

2. Building up worn surfaces on die steel 
castings of the locomotive. 

3. Repairing broken frames and other st,-,- : 
castings. 

4. Fire-box welding. 

.". Repairing of shop tools. 

(i. Welding in side sheets, tube -beets and rlooi 
sheets. 

Metal Electrode I hed 

In practically all railroad work, the metal elec- 
le is used. The Railway Mechanical Engi- 
neer in the issue of November, 1916, savs ■ 

"The metal process usually gives a more re- 
liable weld, gives finer texture to the metal, 
es it less porous, can be more neatly executed 
and finished, requires less power and may be 
easier controlled. The carbon process is well 
suited for filling holes in large castings and 
similar work, but the metal process is best for 
building up metal on surfaces since the additioi 
of metal is largely automatic and the confinement 



16 



RAILROAD SHOP REPAIRS 



. iiiiiiniiiiiiiiiiiiii 



llinill ; Ill 




of the heat avoids flowing- and run-off tenden- 
cies ; in other words the added metal stays where 
it is put. With suitable control provisions it is 
possible to combine methods, heating' the work- 
ing zone by the use of the carbon arc, and build- 
ing up the new metal with the metal electrode, 
the procedure depending upon the character of 
the work and the ability to reach the molten 
condition simultaneously upon object and elec- 
trode." 

The carbon process can only be used effec- 
tively where the work can be placed upright on 
a table and where the casting can be subsequently 
annealed, which practically eliminates its use 
from the Railroad Shops. 

Repairing Breakage 

In repairing broken and worn parts, the prep- 
aration consists mainly in cleaning the piece of 
all traces of oil. rust, etc., before welding is 
begun. Where two pieces are to be joined, the 
edges of the sections are chipped out with a chip- 
ping hammer to provide a "v" shaped gn><>\<' 
at their junction, thereby insuring that the joint 
is completely filled with metal. Where thick 
sections are to be joined, it is often advisable 
to provide a groove in each side, in any event 
the groove should extend entirely through the 
junction of the two pieces. 

In beginning, the arc must reach the bottom 
of the groove. Liquefy the metal at that point 
first. For this reason, the groove between the 
pieces must have an angle sufficiently large to 
allow the operator to get to the bottom. On 
boiler plates, the angle is usually 45 degrees, 
while on large steel castings the angle may be 
from 45 to 60 degrees. 



«r 



MM* 
L 



J 3f ™* 




34. Weld in Locomotive Side Frame. 




Fi 6 



DEFI iKK 



Droken Engine Frame with break cut 
pri pari -I 1< ir welding, 




Fig. 35. AFTER. The Completed Weld. A piece of boiler 

plate is placed around the bottom of the gap as shown in the 

illustration, in order to hold the new metal in place. 




Fig. 36. 



gine Frame repaired by the I. it 
tile Rock Island Shops, 



17 




i tun i ninmiiiii iiiiuill i n iiiiiuiiiiiiiiiinimuiiiimiiimimii iniiiiimiiii liiiiliiiiimiiniliii mimiii 1 



ELECTRIC ARC WELDING 







Fig BEFI IRE. I chipped out 



> ith the hamni 







I ig 



\ INK. 




s A Locoi Sidi Fi ante wit It 

in it. A patch on the mud i 



i'i \ e separate wi Ids 
also be 



(in most work, it is necessary that the two 
pieces first be aligned, and clamped together or 
clamped to a third puce. If a one sided heat 
occurs, some allowance must lie made for unequal 
contraction. This part of the work calls for 
experienced men. If it is desired to build up 
metal of an) height with the carbon arc process 
a mold of asbestos, lire clay or carbon must be 
made to retain the molten material. The work 
of welding should if possible be dime in one con 

tinuous heat. ' >ne g 1 example is given by The 

Railwa) Mechanical Engineer, drawings for the 
job being reproduced on page 18 i big. 39). 

The\ sav regarding this job, "The frame at 
crack is first v'd oul on both sides with the ox) 
acetylene cutting flame, and chipped out with an 
air hammer and chisel to get a clean surface as 
shown at \ in Fig. 39. \ inch plate, about 
1 inch wider than the frame, is then fastened 
to the bottom. From tlii-. as a basis the electric 
welder builds up the full width of the frame 
first mi one side ami then on the other as shown 
at I'.. After the v is filled mi both sides, 8 " ll h 
round bars about 2 inches longer than the full 
width of the v are welded on the outside as i 

ement, starting at the bottom and building 
hi ' i see C, Fig. 39) The very fact that these bars 

round enables the operator to easily and sui 
cessfully weld them in by being able to get in 
around them. The completed weld is shown 
at D." 

The cost table i in page 24 compiled in one of 

the largest locomotive --hops in the country, shows 

the variety of work and the saving over a period 

ven months. The cost of electric current is 

figured at _' cents per kilowatt hour. 




£' Round Bcr Bcve'ed at Ends 



Drawing showing mrlln.il of repairing engine i 
„ v. fi III WA\ VI i HANICAL EXGW1 I 



18 



WELDING CRACKS AND PATCHES 



llllllllllllll :'"i:|i|l|r.'l!liMli!'!lill"lilli-Uiil: !!!■: 



Illlllllllllll Illlllllll illlllllllll 




Flue Welding 

Welding the tines and hack flue-sheet, if prop- 
erly done, will enable a set of tines to go the 
three-year limit without attention in a "good 
water" district. The old practice of rolling a 
few leaky flues after the engine comes in from 
a run, is entirely eliminated by welding. Weld- 
ing flues, however, will not entirely cure the flue 
trouble, which arises from bad water. 

The Welding Committee of the Railway 
Electrical Engineers Association makes the fol- 
lowing recommendations for flue welding with 
the electric arc: "The ideal preparation of a set 
of flues for welding is as fellows: 

1. Put flues in exactly as if the\ were not to 
be welded. 

2. hire the boiler, or, better still, send the 
engine out for a run. The object is to burn the 
oil out from under the beads of the flues and 
allow the flues to take a permanent set. 

3. The flue sheet should then be brushed off 
with a stiff wire brush or sand blasted. The 
object is to eliminate, so far as possible, the 
scale of oxide on the flue sheet and flues. Iron 
oxide is not a good conductor of electricity and 
causes difficulties with the arc which in turn may 
produce a poor weld. 

The welding of 2-inch flues is done best with 
' s-inch electrode. On sand blasted flue sheets 
90 to 100 amperes is enough current. Flue 
sheets that have a thick coat of oxide require 
from 120 to 130 amperes on this size wire. Five- 




Fig. 40. A weld on the calking edge of locomotive boiler outside 
of mud ring. 




*» 



• 0- »■■ „ 9 9 „ 

> » * 

# " * » # . *' 9 

V* *>* '•" 0* 0* r* t' 

..»»«►**> t * * 
<• » * * '.*.*,' 

a»^» a. m r r r f 



il! 41. Flues welded in the back flue sheet of Locomotive 
Boiler by Electric Arc Welding. Flues tr<<|uentlv 
give three years' service, without attention 
when welded in tins manm r 




Fig. 43. Locomotive in the Big Four Shops at Linndale, ' '. 
Leakage in this locomotive has been repaired by welding around 
the steam chest pipe and in the smoke box so that the locomo- 
tive is practically as good as new. 



19 



iniiiiiiiiiiiiiiiiiimiiiitii 



■hi' mimum 




iiiiiiiuijiiimiimii r,|iiiiuiiii!i 



ELECTRIC ARC WELDING 



I. iiiiimuiii 



Hum mi .inn, ifiimtiiimttm ii 



, ■ eptioi al I ■- g of this 

"1 'A illk. 







Fig 45. Welded in locomotive fire box showing two 

patches made wil Ord j tins weld would 

been made but the fire box was 

t.il- en ■ >u1 I 




. 



inch flues should be welded with -/'..-inch elec- 
trode with 120 to 140 amperes depending upon 
the condition of the flue sheet." 

The American Railway Master Mechanics 
Association is very favorably disposed toward 
the use of electric welding and as long ago as 
1912, had recommended its use. Even at that 
time, <>ne road had 200 engines running with 
lines welded in and it was found unnecessary to 
remove tines when engines came in for repairs 
It was found that maintenance cost was almost 
entirely eliminated, engine failures were avoided 
and engines could be kepi in service a greater 
length of time. 

See "Suggestive Applications." Page 49. 



Welding Cracks and Patches 

The welding of cracks and patching of seams 
offer the most difficult problems to the welding 
operator. The Association of Railway Electrical 
Engineers, offers the following directions for 
this class of work: "A crack should be located 
and at least twi i inches bey< ind each end a ' 2-inch 
hole drilled. The edges of the crack should then 
be beveled so that the operator can get at them 
to make the weld. On horizontal cracks, the 
lower edge does not need to be beveled but 
should be chipped to give a square edge. The 
upper edge should be beveled al least 45 degrees. 
Vertical cracks should be beveled from 30 de- 
grees to 45 degrees on each .side. The less ma- 
terial removed from the crack the better. All 
welds should he made with the least possible 
amount of metal between the edges of the orig- 
inal material. 




lg for expansion in side sheets by making the 
weld in the alternate sections 



Fig. 47 



Leaky Rivets in mud ring repaired by building up pad 
around the head of the rivets as shown. 



20 



STANDARD RAILROAD PRACTICE 




"If the crack or seam is a long one, the metal 
>hould be put in alternate sections 4-inches to 
6-inches long. The operator should put one 
layer of metal in each of these alternate sections 
starting near the center of the seam or crack. 
The open sections can then be filled, starting at 
the coolest point. Successive layers of metal 
can then be applied until the seam is completed. 
Wherever possible, at least 30 percent of rein- 
forcing should be applied so that the cross -sec- 
tion through the weld is 30 percent greater than 
the section of the original plate. After each layer 
of metal is welded into the seam, it should be 
thoroughly brushed with a stiff wire brush to 
remove as much of the oxide as possible. Where 
the sand blast is available and can be used on 
the job the results will justify the expenditure of 
time necessary to clean the metal between layers. 
The same general care should be taken in the 
welding of locomotive frames as in the case of 
the boiler plate of the fire box. 

"Aside from the use of judgment in the appli- 
cation of the electric arc welding process, there 
are three rules which the operator must observe 
to get the best results in welding: 1. Hold a 
short arc. 2. I'se a low current. 3. Always work 
on clean metal." 



Provision for Expansion 

■'Where long seams are to be welded, as fin- 
example, in welding in a half side sheet, prac 
tice again differs as to the best method of tak- 
ing care of expansion. Some operators prefer 




Fig. 48 A patch built up around a locomotive mud ring. This 

l-atrb is nearly 8 feet long and made a saving in cost of over 

$2,1100. besides the saving of a month's delay in m.'ik 

ing the repair. 




s •/ I 



Fig. 49. Worn Engine Cross head repaired by welding on piece 
of boiler plate at the top and welding crack a* shown. 




Fig. 50. Arc Welding as used in making smoke box for 
locomotive boiler 




Fig. 51. 



Worn St 

building 



ip worn surface by arc welding. 



21 




ELECTRIC ARC WFI.DIM; 



i - 



Arc Weldei 

R. R n I 



l i 






to allow for expansion by widening the gap 
between the sheet, this being done by setting 
the new sheet away at a slight angle; the allow- 
ance usually made by these operators is about 
! -.-inch to ' [-inch per foot of length. Then 
when the weld is begun at one end and the work 
is carried on, the two edges will gradually draw 
together, due to the contraction in the weld at 
cooling. Other operators prefer to place the 
two edges in final relation to each other, holding 
them at the proper distance apart by mean- ol 
'tacks' at intervals of 12-inches to 18 inches. 
The weld is then begun at either end and as it 
approaches a 'tack' the tack itself is cut out by 
use of a chisel and solid metal welded in. the 
tack simply serving the purpose of holding the 
sheets in proper relation until the weld is made. 
When tacking is used, it has often been found 
advisable to weld a short space, say six or eight 
inches from one end to the seam, then go to the 
other end of the seam .and weld a like distance, 
thus keeping heating and expansion at a mini- 
mum." 



Standard Welding Practice 



® 




, 




Fig ] i:< prompt repan oi broken shop tools is ofti 

great ii in tlu railroad repaii shop. *1> A brok< 

drill socket for 1" diametei drill. A new socket would lo 
$1 80, i an impoi tanl e same 

drill - Lincoln Arc Welder Cost 

pair, including preparation of weld, was 

pipe wrench for 3" pipe, repaired by the Lincoln Arc Welder. 
A new wrench would havi ccst about I lir cost 

20 cents, including preparation, welding and grinding off super- 
fluous metal .a weld. 



Hie Association of Railway Electrical Eng 
neei i ommended the following with refer 

to standardization and shop organization 
based upon the experience of their various mem- 
bers on different r< >ads. 

"The importance of the wadding operations in 
a locomotive shop or engine house is so great 
that it is necessary for the work to be done under 
the direction of a competent and responsible 
member of the radio, id organization. \ very 
i sful solution to this problem has been made 
on several systems by the appointment of a Su- 
pervisor of Electric Welding who is responsible 
directl) to the general superintendent of motive 
power, ddie Supervisor of Electric Welding 
makes the practice of the several shops uniform 
so that the failure of one shop to get results from 
a process can he traced to its origin. The Super- 
visor i if Electric Welding must find a successful 
way of doing each job and require every dun. 
to perform the operation according to his instruc- 
ti' 'tis. 

"Operators are obtained in most cases from 
a shop organization. On roads where an ap- 
prenticeship training is provided most of the 



STANDARD RAILROAD PRACTICE 



iiiiiMiini!! 111 i i' minimi ■ i i ii ■ ' i 



iiiiiiiiiiiiiiiiiimiiiiii i mi ' iimiiiiiiiiiiiiiiiiiimiiiiimiiii 



m ■ ■ mi ■ mm ' 





Fig. 54. Lincoln Arc Welder (Portable Type) with canvas hous- 
ing as used m engine house on Eastern Railroad. The canvas 
keeps out the dust and dirt prevalent around the engine li aise 




Fig. 



Lincoln Arc Welder (Stationary Type) installed 
engine house on large railroad. 



operators are men who have just completed the 
apprentice work. It is desirable to have opera- 
tors who have had general experience in a rail- 
road shop. In shops which have a local elec- 
trician the care of the electric arc welding equip- 
ment is handled by the chief electrician. In 
engine houses the operator of the equipment is 
usually trained to give the equipment whatever 
care is necessary. " 



Standardization of Operati 



(HIS 



The tendency at the present time is to stand- 
ardize the welding operations in the same manner 
that the machine shop and other operations have 
been standardized. Where welding operations 
are thoroughly standardized the work can be paid 
for on a piece work basis. The standardization 
of welding operations is comparatively simple on 
systems which employ a Supervisor of Electric 
Welding. On other roads it is more difficult to 
standardize the operations, but the necessity for 
having them standardized is greater. Ninety- 
five per cent of the electric arc welding done in 
railroad shops is on operations which can be 
standardized. The following factors should be 
determined for. each job of this nature: 1 — Size 
of electrode, 2 — Kind of electrode. 3 — Current 
in the arc, and -I — Time required for the opera- 
tion. 

Equipment 

A thorough discussion of the equipment avail- 
able for electric welding in railroad shops will 
be found on pages 50-56. 




Fig. 56. Lincoln Arc Welder in Rock Island R. R shops, Silvis, 
111., showing the black canvas screen with which the Welder is 
surrounded, thus protecting the eyes of other workmen from glare. 




Fig. 57. Lincoln Arc Welder (Portable Type). This is oni ol 
twenty-three Arc Welders in use on the Rock Island R. R. 



23 






mm iimmmiiiiiiii 



ELECTRIC ARC WELDING 



i (nil n iininminin 



i i i ' minium ■ i inn inn mi in mini .nnin nun n mnnnnni 



Miscellaneous Kiiitkio Welding 

No. of 
Description. operations 

Bumper Beam 1 

Brake Shoe Heads 102 

Brake Hanger Bracket 1 

Crossheads — Piston 1/ 

Crossheads — Valve 22 

i 'rosshead Pins 3 

Deck Castings 7 

Driving Boxes 4 

Driving Box Lugs. 10 

[•"rallies 2 

Frame Cross Brace 1 

Eccentric Blades 5 

Eccentric ( rank 1 

Guide Hay-. 69 

Guide Yoke ... 1 

I .r\ ii- ( omhinatii m 17 

Links 

Link Hangers 12 
Link Saddles 

Miscellanei ius 6 

Quadrants Teetli 3 

Rods Main 9 

Rods— Side- -Grease Plug Holes 106 

Rods- Side Spade I'm Holes 1 

Rod Straps 

Reverse Lever Heels 
Kc\ it-c I ,<-\ ei I - 1 1 1 hes 
Spring Saddles ... 
Spokes -I )ri\ ing Wheel 
•shop I in 1 . and Machinery 
Pail Sheet 
Tumbling Shall . 
Pender Truck Equalizers 
Transmission Hangers 

Total 487 
Net saving foi month. .$1,375 IN 



Locomotive Shop — Name Withheld -One 



Labor 

$ 1.41 

11.79 

.33 

12.96 

J 39 

.S3 

30.23 

2.10 

KIS 

5 11 

2 59 

.96 

.19 

99.52 

66 

2 66 

.144 

1.36 

59 

1.48 

.28 

2.4S 

20.61 

-t 16 
57 

2.19 

mm 

.72 

.33 

3.13 

4.18 



Material 

$ 0.33 

2.48 

.il. 1 

3.29 

.55 

.18 

6.90 

4.20 
.33 

1.25 
60 
21 
.05 
28.91 
.lit 
60 
89 
.in 
in 
.19 
i ; 
75 

2.70 
23 

1.10 
.15 
13 
i,ii 

.13 
0£ 

85 

si I 

in 



$60.62 



1916 

I an ua i . 
February 

\1 .ii i I 
\pril 
Maj 
1 uni 
li.lv 



No of 

operations 

461 

. 453 

584 

525 

487 

57') 
. 525 



. i oi s Jobs. 



1 ,abi ir 

253 57 
172.92 
228.22 
210.09 
165.97 



Material 

$47 88 
59.89 

64.57 
42.62 
60.62 
54.94 
41.12 



Current 

$155.70 

187.70 
199.13 
] 14.20 
175.52 
175.5-' 
135.62 



Current 

$ 1.35 

9.55 

.08 

10 53 

1.95 

.53 

20.70 

1.80 

.88 

4.20 

1 .80 

.86 

.15 

86.33 

.30 

1.75 

_' 55 

.90 

.45 

.50 

.23 

2.18 

10 05 

08 

3.30 

.45 

.53 

1.80 

4.20 

.50 

.15 

1.00 

3.15 

.38 



Total cost 

$ 3.09 

23.82 

.43 

26.78 

4.89 

1.54 

57.83 

8.10 

2.29 

10.56 

4.99 

2 05 

.59 

214.76 

1 oo 

i.99 
6.68 
2.56 

1.14 

-'17 

56 

5.41 

55 54 
1.56 
8.56 
1.17 
1.32 
4.59 

11.71 
1.35 
.55 
4.98 
8 15 
1.05 



Month. 

Other 

method 

$ 5.00 

80.58 

1 25 

133.06 

13.95 

4.47 
484.32 
105.48 

6.90 
57.84 
21.75 

5.44 

12.74 

423.03 

■'.74 
3257 
36.41 

324 

8.52 

4 St. 

2.45 

9.99 
89.04 
12.29 
53.78 

7.S0 

11.55 

22.99 

42 5(1 

6.00 

1.50 
49.21 
78.30 

1.38 



Saving 

$ 1.91 

56.76 

.82 

106.28 

9.09 

2.93 

426.49 

97.38 

4.61 

47.28 

16.76 

3.41 

12.35 

208.27 

8.68 

27.58 

29.73 

.68 

7.18 

2.69 

1.87 

4.58 

55.70 

10.73 

45.22 

6.63 

10.23 

18.40 

30.70 

4.65 

.97 

44.23 

70.17 

.33 



$175.52 $464.36 $1,839.54 $1,375.18 



Total ei ,-t 
$386.65 
4<o.t,7 
517.07 
349.74 
464.36 
440 55 
342.71 



method 
$1,176.58 

1,871.44 
1,232.65 

1.850.54 
1,726.10 

1.501.53 



Saving 

$ 789.95 

1,092.89 

1,354.37 

882.91 

1.575.18 
1.2S5.55 
i. 158.62 



Saving per 

operation 

$1.71 

2 S2 
2.32 
2.72 

2 s: 

2.22 

7 7 1 



Totals 



3,392 



$1,431.72 



$371.64 $1,163.39 $2,966.75 $10,906.20 $7,939.45 



$2.34 



1 m:i i I Statement of Work Performed with Electric Weldi k ai I motivi Shops. 



No r 
ISIS engines 

Pwtal for 2 in flue; -47 

Total f'T VIII flues l'»i. 

Tola] for -in. 'I- ii-ii, ii. , 

lubes 244 





Actual 








Total 


Time 






n,, ,,r 

flues 

wet led 


time 

iv, Iding 

lir. and mln. 


Latxir 


M it.li.il 


Current 


actual 
welding 


preparing 

for welding 
hr. and mln. 


preparing 

for 
wtldlng 


Total Average 
cost to •>*<. per 
engines engine 


42,640 


2,811' 15" 


$990 77 


$181 09 


$843.72 


$2,015.58 


222' 45" 


$80.39 


$2,093.97 $8.48 


5,034 


1,473' 45" 


520 01 


s. : -17 


442 If, 


1,047.64 


24' 00" 


10.08 


1.056.12 5.J9 



24 



'i iiiimiiutii 



illlHIMIItHI 111:1111. !|IIIINIi:< ■ ■' .:lli.;:,' 



Illlllllllllllllllflllllllllljllll 



' 



COSTS AND SAVINGS 



... . .. 



iniiiiiriiiiiiii niiiimiiiiiiiiiiin .1 



111 inn 1111 mm 1111 1111 mini 




Table 



-Comparison of Electric Weldini; vs. Old Methods and < 



l >• scription of parts Cost old 

method 

\ alvt steins $16.28 

Eccentric straps 1 7.95 

Cylinder cocks 1.36 

Cross heads 355 40 

Piston heads 47.93 

Motion saddles g.32 

Frame braces 99.50 

Crank arms IS.s ] 

Rocker box castings 4 59 

Transmission bar 2.80 

Reach rod [.25 

Rocker arms 20.75 

Eng. truck equalizers 7.70 

Truck frame 15.70 

Trailer jaws ' ~,t. 

Extension piston cross head 6.30 

Brake beams 1 ,59 

I '.rake hangers 5.10 

Smoke arch brace 3.511 

Air pump valves 2,50 

Lugs on valve yoke : 32.45 

Push car wheels 6.Q0 

Stilson wrench 1 ,60 

Drill chuck 15 mi 

Driver brake fulcrum 5.52 

Wheel spokes 1 ,276.80 

Main rod blocks ._, 15.88 

Triple valve gage 20.00 

Link blocks 72.24 

Lift shafts 23.98 

Quadrant 7.43 

Wedges 55.94 

Chafing castings g 30 

Plugging and building up holes J49.69 

Tire rim keys 3.22 

Throttle stem I 50 

Reverse lever support 3.38 

Smoke box 61.38 

Hub liners I J 5 1 

Strip on cross heads 2'~> $2 

Fire door handle 1.75 

Boiler casings 63.21 

Frame buckle 4.90 

Trailer yokes 5.25 

Motion frame 9.10 

Combination lever 1.03 

Lugs nn trailer bub 4.50 

Center castings 76.81 

Spring bli icks 1.15 

Guide blocks 5 52 

Hinder 5.19 

Steam pipes 3.79 

I lat Spots on tires 99.86 

Cylinder bushings 35.65 

Building up side rods 93.48 

* irease cups 1 1.79 

Stationary fire door 8.00 

Cracks iii tanks 372 69 

Petticoat pipes 140.52 

Filling worn spots 2,677.80 

Pins 70.66 

Reverse lever parts 103.02 

fntal $6,434.10 



Ias Welding Made on Ro< k 


Island Lines 






Saving 






( ost gas 


^ ..M . lei . 


over "1.1 


Saving 


No 


welding 


welding 


method 


over gas 


engs. 


$15.26 


$4.76 


$11.52 


$10.50 


6 


7 63 


2.38 


15.57 


5.25 


2 


1.04 


.34 


1.02 


.70 


1 


120.23 


37.73 


318.67 


X2.50 


13 


32.74 


ln.24 


37.69 


22.50 


4 


10.94 


3.44 


4.88 


7.50 


1 


48 "(I 


15.00 


84,50 


33.00 


10 


26.14 


S.14 


10.67 


18 00 





7.29 


2.04 


2.55 


5.25 


1 


4.33 


1.38 


1.42 


3.00 


9 


1.09 


.34 


.91 


.75 


1 


1.1.24 


4.24 


16.51 


9.00 


6 


17.24 


5.24 


2.46 


12.00 


9 


13 04 


4.04 


1 1.66 


9.00 


3 


4.38 


1.36 


1 4" 


3.02 


1 


4.36 


1.36 


4.94 


3.00 


1 


2.18 


.68 


1.01 


1.50 


1 


7.45 


3 4ii 


1.70 


4.05 


3 


6.25 


2.14 


1.36 


4.11 


1 


1.33 


.53 


L.97 


.80 


1 


21.80 


6.80 


25.65 


15.00 


6 


10.56 


3.05 


2. ')4 


7.50 


4 


1.09 


.34 


1.26 


.75 


1 


2 18 


.68 


14.32 


1.50 


1 


8.72 


2.72 


2 xo 


6.00 


1 


113.08 


35.08 


1,241.72 


78.00 


15 


28.34 


0.84 


7.04 


19.50 


9 


3.27 


1.02 


18.98 


2.25 


1 


51.49 


15 4'' 


56.75 


36.00 


20 


4 02 


1 02 


:: 96 


3.00 


1 


11.09 


3.59 


3.84 


7.50 


3 


69.69 


21.69 


33.35 


48.00 


25 


10.70 


3 20 


5.10 


7.50 


1 


280.94 


141) 47 


209 22 


140.47 


70 


5.38 


2.38 


.84 


3.00 




! 09 


.34 


1.16 


.75 


1 


4 36 


1.36 


2.02 


3.00 


-> 


32.43 


9.03 


51.45 


22.50 





13.11 


4.11 


8 411 


9.00 


3 


31.00 


12.66 


12.66 


18.34 


3 


1 09 


.34 


1.41 


.75 


I 


30 30 


•i 32 


53.89 


20.92 


1 


2.41 


.91 


3.99 


1.50 


1 


6.45 


1.95 


3.30 


4.50 


1 


10.17 


4.17 


4.93 


6.00 


1 


1.75 


.55 


48 


1.20 


1 


4.52 


1.52 


2.98 


3.00 


i 


28 56 


9.06 


(.7.75 


19.50 


3 


1.09 


.34 


.81 


- z 


1 


4.29 


1.29 


4.23 


3.00 


1 


13.10 


4.10 


1.09 


9 mi 


2 


5.12 


2.12 


1.67 


3.00 


1 


95.77 


29. 77 


70.09 


6l 


4 


9.40 


3.40 


32.25 


6.00 


1 


81.1 6 


31.16 


62 32 


50 00 


-i 


11.43 


3.93 


7.86 


7.50 


^ 


8.72 


2 7 i 


5.28 


6.00 


1 


113.62 


36 16 


337.53 


78.4,-, 


14 


52.37 


16 37 


124.15 


36 mi 


18 


1,064 60 


329.60 


2. 348 20 


735.00 


128 


87.23 


2 7.2.1 


43.43 


60.00 




74.04 


2 3. '14 
$921 -.1 


7". '18 


51.00 


38 


$2,755.74 


$5,512.49 


$1 





Table II. — Comparison of Elei rRic Welding vs. Other 
Methods. 



( '..St of Cost of 

Description of parts other methods elec. weld 

Pedestals $645.00 $45.24 

Tank frames 9.03 1.36 

Shop tools 14 36 3 4ii 

Piston rods 78.64 16.37 

Sharp flange drivers 165.40 20.28 

Truck side 194.00 10.20 

Building up dr. axles.... 121.50 4.90 

Steel car underframe. . . . 11.34 1.71 

Building up car axles 515.00 25 24 

Hushing stavholt holes... 294.96 73.74 

Welding flues 2,607.65 521.53 

Frames 931.00 133 28 

Cracks in fire boxes 2,431.27 297 17 



Total 



$7,839.15 $1,154.42 





No 


Savings 


engs 


$599.76 


5 


7.67 


1 


30 96 


4 


62.27 


10 


145.12 


3 


183.80 


4 


1 16 60 


1 


9.63 


1 


289.76 




-. i ] n 


26 


2,086.12 


102 


797.72 


1 1 


2.134.10 


92 


$6,684.73 





Table III. Summary. 

ists and Savings Per Month 



Cost 
of other 

in. tit. ids 

$6,434.10 

7.S39.15 


Cost of 

Eras welds 
$2,7 55 74 
3, (.'17. 42' 


I ost 

Of electric 

welds 

$•121 61 
1,154.42 


Saving 

over other 

methi ids 

$5.512 4" 
6,684 71 


Saving 
over eras 

weld 
$1,834.13 

.' 143 00* 


$14,575 2 5 

$77,209.20 

94.069.80 


$6,453.16 

i 'osts am 
1 1 068 84 
44,369 04 


$2,075.03 
Sazings — P 
$1 1,059 S2 

13.853.04 


$12.19; ' 
'r Year 

$66.14'i 88 
S0.21t,,76 


$4,377 1 < 

$22,8fl».56 
30.516 90* 


$171.27'' in 


$77,437.88 


$24,912.36 


$146,366 04 


$52,525. 5. 



•Figures show cost of gas weld if work could have been weWed 
with gas. 




nil iiiMinii ii i i i) i! ii i .i in : iiiimiiiiiiiiiwiimii 

ELECTRIC ARC WELDING 



I iiMimini iimiiiii fn 






Ship Building and Repairing 




Kig. 58. Electric . I motor tru ["his F The Boom Roller & We 

Clevi Ohio, and is doing limit worl the largesl steamer on I 

equipmi H. P Novo Engine hell connecti I Lincoln A Weldei ["hi engine also 

atcs ,,, hammer. I carries the welding 

entei i ip through tl : in the sid: 



Closely allied to it^ use in railroad shops is 
the use of arc welding in shipbuilding and 

repairs. 

Here again tremendous developments have 
taken place in the year since the United States 
entered the war. Very wide use is now being 
made of electric welding in the actual construc- 
tion of >liips, where it not only costs less than 
riveting, but makes a very vital saving in time 
Unfortunately censorship rules will not permit 
the photographing of this work or the givii 
detailed information concerning it. Ship build- 
ers who are interested, however, can obtain all 
the data from the Emergency Fleet Corporation, 
ami the wonderful possibilities of this process in 
ship building will be substantiated by any one 
who takes the pains to thoroughly investigate it. 

At the present time the insurance rules do not 
permit the welding of any strength members on 
the vessel, that is, the welding of plates ,,,- ribs. 
or the welding of the plates to the ribs. 

Regarding this use of electric welding, James 



G, Dudley, Research Engineer, has the follow- 
ing to say, in a recent issue of International 
Marine Engineering: "bur more than five years 
past, railways of the United State- have 
employing metallic electrode welding in largely 
increasing amounts and with astonishing tech- 
nical and economic gains in securing practicall) 
leakless conditions of tubes and furnace sheets 
i if the 1< ii omi 'live In liters. 

" ['lie technical literature of railways and weld- 
in- demonstrates beyond successful controver- 
sion that jointures of mure than 100 percent effi- 
ciency can be readily and commercially secured 
by electric welding means. Even the truly re 
markable results secured under the punishing 
conditions of steam locomotive service have not 
as yet overcome the friction and inertia of 
"standard practice" in so far as the design and 
fabrication of a complete locomotive is con- 
cerned, but eventually the insurance and inspec- 
tion interests must voluntarily "approve" or be 
compelled by the march of events to "permit" 
the fullest possible use of electric welding in this 
field of transportation. 



26 



SHIP BUILDING AND REPAIRING 



mil : minimi 




"Passing to marine practice, it is more or less 
common knowledge in marine circles that elec- 
tric welding has been successfully and economic- 
ally employed for main- years past in man) ports 
of many countries in repairing of parts of ships, 
winch otherwise must have been tied up for 
costl) periods." 

At present the rules permit the welding of the 
following parts, and these after all are of very 
great importance because they are the parts on 
which riveting takes the must time and on which 
the greatest saving can be made: 

The classification societies have so far con- 
sidered and approved the application of electric 
welding to the following parts of vessels: 

Deck Rail Stanchions to plating. 

Clips for Detachable Rail Stanchions. 

Continuous Railing Rods (Joints). 

Attaching Deck Collars (1,. Kings i around ven- 
tilators. 

Attaching Deck Collars (L Rings) smoke stack. 

Attaching cape rings, smoke stack pipes, etc. 

Attaching Galley Fixtures to Plating. 

Attaching Bath and other Fixtures in officers' 
quarters. 

Attaching Cowl Supporting Rings to Ventilators. 

Bulwark Top Splicing and End Fitting. 

Skylight^ over I ialley. 

(a) Engine Room Stairs and Gratings. 

(b) Boiler Room Stairs and Gratings. 
Attaching (A) and (B) to Plating Grab Rods 

on Casing. 
All Stairs and Ladders including Rail Attach- 
ments. 
Door Frames to Casing, Hinges, Catches lh>ld 

Coach-hooks, etc. 
Clips f"r attaching Interior Wood Finish to '• S 

ing. 
Entire Screen Ubd. 
Coal Chutes. 
Butts of W. T. and O. T. Boundary Bars on 

Bhds. or floors in double bottom. 
Ventilator ( owls. 
Stacks and Uptakes. 
Bulkheads (that are not structural parts of the 

ship), partition bulkheads in accommodations. 
Framing and Supports for Engine and Boiler 

Room Flooring or Gratings. 
Cargo Batten Cleats. 




Pig. 59, The sketches show pieces which can he made with the 
i lectric arc in ship yards. No 1 is a very difficult and expen- 
sive job for the angle smith, but can he made for a few cents 
with the electric arc weider, No. 2 is a boat davit made from 
an 8 inch I beam split and rewelded. The cost of this from 
the angle smith would be $6.00 or $7.00. whereas it can be 
,1- , li i, «< 1 . 1, . 1 for $1-00. 




Fig. 60. Welding a sky light on a steel vessel. 




Tic 61 Sky light c pli ti Ij v i Ided. 




urn u urn' ■linn: mil .iM ■ ■ '■ - ■ i ! 



ELECTRIC ARC WELDING 



iiii. ":. 



i m iiii , 



Fig. 62. Model -i I- li < trie Weld, d K 

I I il-- ...lih i .1 t : • 

Tanks (that arc not structural parts). 

Shaft Alley Escapes. 

Steel Skylights over accommodation spaces. 

Engine Room Skylights. 

Grab Rods on exterior anil interior of Deck 

I louses. 

Deck Houses noi covering unprotected openings 
through weather decks. 

Reinforcing and protecting angles round man- 
holes. 

[oints of \Y. T. \ngle Collars at frames in wav 
of W T Flats. 

< >ther parts of a vessel in which electric welding 
is proposed must be submitted for considers 
tion. 

March 2^, 1918, Llo\d's Register of Shippin 

i j Battery Place. .V. Y. ('. 

It i- the < >i >mi> 'ii hi' experts on the "Electric 
Welding ( ommittee of the Emergency Fleet 
Corporation." thai four welded ships can be 
built for the cost of three riveted ships and tin- 
welded ship will require about half the time for 
complete fabricate »n. 

The British Admiralty have already launched 
a channel barge of some 200 tons dead weight 
built completely by the electric welding process. 

Plans have been submitted to the Fleet Cor- 
poration for a 7500 ton electrically welded mer 
chant ship of standard construction which would 
make use of the steels already on order and 
would he built in a yard designed especially for 
the construction of electrically welded ship- 
It is estimated that on continuous welding — 
side and down welding, an average speed of 4 
feet per hour could he maintained and that on 



overhead or intermittent welding a speed ot 2 
feet per hour could he averaged. 

To give an idea of the work involved, a ship 
of this character would require the equivalent 
of about 186,000 lineal feet of welding in half 
inch plate, and the number of rivets to lie driven 
in the yards and on the ways would he reduced 
to about 17, (hh). Tin's i- an extremely important 
development in view of the difficulty ot obtaining 
riveters and the unusually high wages paid for 
this class of work. Hue to the saving in steel 
weight resulting from a re-distrihutioii ot mate 
rial and a substitution of welding lor riveting 
joints, it is estimated that a welded vessel would 
have 500 ions more cargo capacity than a riveted 
ship of the same dimensions. 

According to the best available information 

the cost of welding on such a ship Would he 

,-ihi >ut $41.00 per ton of steel. Figuring the high- 
est possible prices for labor, material, etc., and 
that this figure might fairly be expected to he 
reduced to $29.50 per ton. added to ibis would 

he the o >st of shop preparation for welding, erect 
ing and fitting the plates in place, which would 
give a total cost of $87.00 per ton t not including 
steel), at a maximum, with a fair chance ni 
average- cost as low as $75.50 pel ton 

Inasmuch as there are only 2300 ton- o! steel 

in the welded ship as compared with 2800 tons 
for the riveted ship, the total cost of all work- 
should he considered in making comparisons and 
not the Ci ist tier ton. 

\ recent issue of the Welding Kngineci 
tains some valuable suggestions for arc welding 
mi ship building work. Especial mention is 
made of the fact that steel foundries are now 
working at full capacity and that the linn- c m 
sumed in sending hack defective castings to them 
is wasted. Electric welding equipment for im- 
mediate repair of these castings should he in- 
stalled in the ship yards and the transportation 
conserved. 

A number of pieces which can be welded •- 
g 1 advantage are shown in the sketch here- 
with, reproduced by the courtesy of the Welding 
Engineer. All of these pieces can be welded and 
are bein' r welded in some vards. Such welds an 



28 



iiiiliimwiiitiiimiini, iiinnmmiiuii mini 



HlltllllllttllllllllllltltlllllllllimilllHIIIIIIIIIIIIIIIIIIIIIIIIII! 



uiiiihuin, :: . in in iiMiiiniiii nun in, Miiinj'iiiimiiin 



inn; :n ■ . mi miiiiii 



SHIP BUILDING AND REPAIRING 



mm vim'. in milium 




perfectly reliable, providing the operator is care- 
ful and good material is used, precautions which 
must be observed on any kind of mechanical 
work. The metal electrode is the only suitable 
method for welds of this character. 

Repairs 

The most important work done bj the arc 
welding process on board ships is in the reoair 
of the ship's boiler. Owing to the strain which 
is brought to bear upon the shell and fire box 
of the boiler, due to the heaving, rolling and 
pitching of the ship, there is a greater tendency 
for the riveted joints and stay bolts to leak than 
in the case of a stationary boiler. Also, as a 
general proposition marine boilers work harder 
for their nominal rating than stationary boilers. 
This means greater corrosion and more rapid 
deterioration. 

In general, the two classes of defects which 
occur are cracks in the furnace and leaks in the 
riveted seams and stav holts. The United States 
government has very strict rules regarding the 
application of the process to the welding of 
marine boilers, but the defects just named can 
be repaired by the arc welding process. Tn the 
case of a riveted seam which leaks due to the 
fact that the caulked edge has worked away from 
the plate a reinforcing strip is usually put on 
the seam, extending from the extreme edge of 
the caulked edge to a point beyond the heads of 
the rivets. This will effectively stop all leaks 
either around the rivets or at the caulking edge. 
Where the edge beyond the line of rivets has 
been eaten away by the corroding action of leak- 
ing steam a whole new edge is built up. all work- 
being done by the metal electrode process 

Leaky stay bolts are repaired by reinforcing 
and welding clear over the top of the stay bolts. 
Cracks in the fire box are first located and holes 
drilled in the shell at each end of the crack to be 
sure that the end of the crack has been reached. 
Then the intermediate space is chipped out giv- 
ing two beveled edges. 

The electric arc process is used almost ex- 
clusively for this work, for the reason that it 
is almost impossible to do the work with the 
oxy-acetylene, and a good many United States 




fcrn>/-«rfrnAi»-t- 


\ 



Fig. 63. Repair Tug, Carrie A Ryerson, property of A. F 
Mitchell & Son, Chicago This tug carries a 200 ampere Lincoln 
Arc Welding outfit in the small housi on the deck. This Welder 
is driven by a Novo Gasoline Engine and by actual test it 
performed th< same amount of wink on 6 gallons of gasoline 
as a constant voltage type of welder owned by t Fie same 
company, driven by a strain turbine and consuming 2 tons of 
coal. (See page 50 52 for description of Constant and V i 
Voltage Welders, > 




I ig. 64. Broken stern post on S. S. Cygnus before weld- 
Note that the break has been chipped out to a "V" 
shape for welding. 




Pig. 65. Stern post on S. S, Cygnus (set Fig, 64) The weld 
was made with a Lincoln Arc Welder and was practically com- 
pleted when this photograph was taken. 



29 




ELECTRIC ARC WELDING 



in iiiii mini nil in 



Government steamboat inspectors refuse to pass 
the work of the oxy-acetylene operator for this 
purpose. Tin- trouble arises from the wide dis- 
tribution of the heat i if the oxy-acetylene flame 
which causes contraction difficulties in the plate 
i if the hoiler. \nother serious defect < if the oxy- 
acetylene process is that it is almost impossible 
to weld overhead with the use of the gas flame. 
Vbout one operator out of fifty can do success- 
ful work in the overhead position. Since a large 
part of the boiler work encountered in marine 
practice is overhead, this practically eliminates 
the oxy-acetylene process. The fire rule- pro- 
hibit it-- use in mi ist instances. 

A great deal of welding is done on the 'leeks 
and deck houses of boats. Most of this work 
at the present cine is in the nature of repair 
work rather than new construction. On board 
the ship- of the Great I .tikes a great deal of 
welding is done about the hatches which become 
damaged from loading and unloading. Miscel- 
laneous small jobs are done about a boat when it 
is laid up f"t repairs, winch mean a great saving 
of time and money. While at the present time 
there is very little welding' done on the outer 
shell of the hull there is considerable work being 
done about the engine room, .ami on the arches 
and tank tops. < hie of the latter applications is 
in burning off rivets where certain plates are to 
be taken off and new plates put on. Where a 
rivet is to be driven it is necessan to gel one 
head of the ri before it can be taken out. 

Burning off the head of the rivel and then driv- 
ing it through is the quickest iv; i ed up to 
the present time for doing this job. Another 
application of arc welding when the boat 1- in 
drydock is the repairing of what is known as 
the rudder shoe. This 1- the heavj steel casting 
which extends from the -tern end oi the keel 
of the ship to support the rudder post. It is 
ther frequent occurrence for this -hoe to be- 
come broken and it is necessary to drydock the 
ship m order to repair it. This job was formerly 
done with the thermit process, but has been done 
successfully a number of times with the carbon 
arc process. The rudder frame is usually a steel 
casting with boiler plate riveted on it. In col- 
lision- and wrecks the rudder frequently sutlers 



and repair- are made using the arc welding 
process, 

While a great many applications of the arc 
welding process have been made up to the pres- 
ent time in shipbuilding and repair practice, there 
1- no doubt but that only a few of the possible 
applicatii ins have been made. 

Equipment 

Up to the present time the equipment used 
for arc welding purposes in marine practice has 
Keen n! three types The engine driven unit. 
direct connected to a reciprocating engine: the 
belt driven engine type unit, and the turbine 
driven engine type unit. The equipment is 
usually mounted on a boat which is self-pro 
pelled by its own -team engine. The boat must 
carry a licensed engineer in addition to one or 
more boiler makers and one or more operatoi 
the arc welding plant. The charge for the 
ervices of the repair boat varies somewhat in 
different localities. ( >n the Great Lakes a great 
deal of contract work is done, that is, a price is 
given on each proposed job, and there really is 
Hi 1 standard price. 

The arc process is used rather than the oxy- 
acetylene process for marine work because the 
most important part of the work — boiler repairs 
— can be done only by the arc process. The cost 
of producing the heat for welding is certainly 
igh with most electric outfits now in opera- 
tion as it would be if the gas could be used. This 
high cost of producing the electric power is due 
to the high investment in the repair boat, the 
emergency character of the service rendered, 
which mean- that the boat lies idle a good per- 
centage of tin- time, and the practice of using 
m driven equipment on a -elf-propelling boat. 
But "wing to the fact that boiler repairs cannot 
be successfully done by the gas process and the 
enormous saving resulting from the application 
of welding in repair work, the electric welding 
outfit ha- become a recognized ami indispensable 
part of the ship repair company's equipment. 
The actual cosl per hour per operator mi a -team 
driven outfit which include- air tool equipment 
varies of course with the continuity of the work. 
( )n the Great Lakes the actual cost per operator 



30 



SHIP BUILDING AND REPAIRING 



■ li 1 ■ iiimi::i mmm 1 :■ 



: [hum si ■ i' ■ in! 1 ■ ■ ■ ■ ■ ■ n ■ ! i 111 ii mum minim i in minimum iiiiiiiiiiiiimiiminm 






Fig, 66. Welding a coal shovel in the Great Lakes district. Arc 

Welding can be (lone at any point where an electric cable 

can be carried. 




t 



Fig. 67. Lincoln Arc Welder direct geared to a 10 H. P. Novo 

Gasoline Engine, making an ideal outfit for ship building and 

repair work, where a portable outfit is required 



per hour, considering investment and the varia- 
tion in the amount of work dune is probably 
not less than $2.50 per operator (1916). The 
cost of operating the air compressor is an addi- 
tion to this figure. The cost of operation in 
harbors on the sea coast probably does not ex- 
ceed one half the above figure on the average, 
due to the greater amount of work. Gasoline 
or oil driven equipment can he operated at a 
figure in the neighborhood of $1.00 per operator 
per hour, owing 1" the fact that a licensed engi- 
neer is not required. Tins type of equipment 
is to be recommended for small welding repair 
companies in all eases. The steam equipment is 
economical however, for large ship repair com- 
panies i in the sea coast. 

Regarding what to specify for marine work, 
it is recommended that in all cases individual 
units he used; that is, an individual unit for 
each operator. Unless the individual units are 
used, a machine of considerably greater capacity 
must he installed in order that there will be no 
interference of one operator with another. Since 
a large part of the work done on board ships 
is done with the metal electrode process, 150 
ampere capacity represents the unit capacity 
required. 

Equipment 

A description of the various types of arc 
welder adapted to shipbuilding and repair will be 
found i in pages 5' l-5< i. 



31 







II I..IM..-.MM. -in: .-:■■■ - ■•■■: -in Mil Mlliili II mil 



■■ M '■ IN ■ ■■: 



ELECTRIC ARC WELDING 



■ '! ri '■ : :. 'Hi 'Hi ■ llllimilll II I .:■ ■ J IIIIIIUHIH ■ 



Boiler Plate Work 




w 

general 



Welder at I 
Ohio. This Coi 

\ \ 

md. 




In locomotive shops of the large railway sys- 
tems of the country, the arc welding process has 
been used for a period of from six to eight years 
and in many shops the process is used not onI\ 
in the repairing of old boilers, but in the manu- 
facturing of new "ins. The work in repairing 
"Id boilers may be grouped under the head of 
welding in lines, welding in tube sheel and • 
ing cracks in the fire 1» ex. 

See "Suggestive Applications," Page 49. 

It lias also been widely used for general tank 
i - ork The American Machinist, in a recent 
issue, presents quite a discussion on this use of 
arc welding, stating: "Nowhere is the saving 
of are welding exemplified to a greater e? 
than in tin- manufacture "i steel tanks. Not 
only have the actual manufacturing operations 
been simplified and cheapened hv the elimination 
hi riveting and caulking, hut the resistance of 
the finished weld to leakage or rupture is much 
greater than that of the riveted joint." 

At a recent meeting of the Boiler Code Com- 
mittee of The American Society of -Mechanical 
Engineers, the following fact- were presented 
li\ speakers before thai committee bearing par- 
ticularly on the use (if welding for boiler and 
similar high pressure vessels. 

"The recent improvements in the an uf weld- 
ing in the apparatus and in methods of testing" 
the product, notably in the electric are pro* 
have made it possible t<i make welded joints 
which are stronger and more reliable than riveted 
joints and that the formerly accepted idea that 




Fig. 69 An Compressoi with resi made liy The Leader 

1m. ii Works, Decatur, 111. Ever) - im in (lie link ^ welded 

with i \ , w , :. :. VVeldei is uj 

theii work with great success. 






: I i ■-■■!< Vessel made by Arc Welding, at ■' 

the Leader Iron Works, Decatur, 111. 



32 



'""" ' ' ' '" '"" ««""« »'» i i i»» Mil »»i UIIMIIH II Illlll I , ,1, i ,,„„ , .„„ i „,„„„„ ,„„„ 



BOILER PLATE WELDING 



iiinmniimii "' mm " ' i' iiiiiiii i mini i i illinium 



| ' i mil rn 



the welded joint is an "unknown quantity" has 
been disproved by present day practice. ( In this 
connection, photo-micrographs show that the 
thermal disturbance in the metal adjacent to the 
weld is negligible in the arc process and that the 
crystalline structure of the metal in the weld is 
that of normal cast steel). 

"The autogenous welding processes are being 

used extensively in all kinds of high pressure 
vessels. 

"A manufacturer of such vessels has more 
than 2,500.000 in service to show that the per- 
centage of failures on welded vessels is actually 
lower than on riveted vessels. The period cov- 
ered by this manufacturer's experience is fifteen 
years and both electric arc and oxy-acetylene 
processes were used. 

"The demand fur large high pressure drums 
has reached the point where the thickness of the 
metal required to withstand the pressure is too 
great to be riveted owing to the excessive thick- 
ness of the metal obtained in the joint and the 
consequent difficulties encountered in exposing 
such a joint to the fire. The obsolete forge weld- 
ing process does not offer a solution to this prob- 
lem because of the unreliability of welds and the 
impracticability of welding vessels of such size- 
in this manner. The autogenous welding proc- 
esses offer a reliable and entirely practicable 
means of welding such vessels regardless of the 
thickness of the plate or size of drum." 

The boiler shop does nut, of course, confine 
itself to making of boilers and pressure vessels. 
In a great deal of the other work the boiler simp 
does, the electric are is especially adapted. This 
includes the manufacture of the following class 
of articles : 



Tumbling barrels 
Revolving driers 
Vats for breweries 
Tanks, vats and Hues 
Industrial cars 
Dump cars 
Clamshell buckets 
Converter shells 
Spelter tanks 
Annealing pots 
Transformer housings 
Oil refinery equipment 
Sugar refinery equipment 



Cotton mill equipment 
Special bodies for automo- 
biles 
Concrete mixers 
Tank cars 
Steel gondolas 
Steel box cars 
Gasoline tanks 
Feed water beater-. 
Wagon tanks 
Fan and blower cases 
Hydraulic accumulators 




Fig. 71. Rotary Cement Kiln ni.uk- of 1 : 4 nut 
w-uli the Lincoln Arc Welder. The weld 1-- only 
plcted and the "V" shaped joint before welding 
at the right. 



mi tialh corn- 
eal! bt 1 - 





Fig. 7}. Tup nf oil still showing wilding, which makes these 

slills vapor tight. The .Standard Oil Co. use tin- Lincoln Arc 

Welder on all their stills. 



33 



Ill, III II Illl . II !. ■ ' ill' ■ ■ Ill' 




■ HMIIH'ilil ■ I!' c: i: ■ 



ELECTRIC ARC WELDING 










Tn thi> work, electric arc welding comes into 
direct competition with riveting and for that 
reason a comparative cost of the two processes 
i- of interest 

Cost of Welding and Riveting 

In order to compare the cost of riveting with 
the cost of welding we max lake the amount of 
ivork accomplished under given conditions bv 
the riveting gang, analyze the cost of the work 
and compare it with the cost of doing the 
work with the arc welding process. Taking the 
thicki the plate as ,',, -inch, spacing the 

rixcts at l'j-iiicli. the size of the rivets at 
ii li in diameter, we can safely estimate that the 
riveting gang will put in 60 of these rixcts in 
ne hour, under ordinary shop conditions. The 
analysis of the a >st is as f< ill i\x - : 

' es base 1 i >n o inditii ms in 1' '16. 

RIVETING 

maker's time, ■ $ .45 

ne In mi ,.<5 

Mix et heater's nine i me hi mi .21 1 

lr 'in 

( Ine lax '"" man's I ime, hi mi .2 ! 

|)unchmen's i ime, ' j In nir .17 

r 1 1 " ii i .20 

i >)11 men's timi . . hi mi .20 

Total Labor $2.03 

I ength ' if rix eted seam, 7 ft 6 in. 
I 'i mn I ets i equin i 

■ rivets, 1 

Power required to drive pneumatic hammer and 

ioI, appri iximately In K. VV. Imurs. 

Investment per riveting gang, in air compressors, 

motor drive, storage tanks, distributing 

svstem, air hammers, and other rna- 

• 







I' 

U i Ming. 







ncoln \rc Weldei a .ii the shop of Tin 

* leveland. In the foreground are stiffening 
mil;-- for boilei work made with the Lincoln Arc Wi 
ised in this ^hop for a wide varietj of work 



34 



COMPARED WITH RIVETING 



urn [ I ' .1. iimiiiiimiiiii 



i ' i mi 




Iii order to get a comparative cost of the arc 

welding process, we will analyze the cost of 
doing the same work, namely making a seam 
7 feet 6 inches long, which is a lap joint, welded 
inside and out. The following is an analysis of 
the cost, also on 1916 conditions. 

ARC WELDING 

One operator at 45c per hour for l'.j hours $ .56 

No bucker required 
Xo heater required. 

One man with a chipping hammer, ' _■ hour 2.3 

i )ne layout man. '.J hour 11 

Two punchers, % hour. 08 

Two erectors, ',, hour .Ill 

T\\ i 1 p ill men : j hi iur Jn 

Total Labor $1.28 

Pounds of electrode required. 2.S. 
Cost of electrode, 12.5c. 

Kilowatt hours required to run the welder, ap- 
proximately 5. 
Investment in welding machine for one man. .. .$860.00 

Labor has advanced considerably since this 
time but riveting gangs wages have gone up 
far more than welders' waives so thai the com- 
parison is very fair. 

It is to be noted from the above analysis that 
the labor cost item in the manufacture of boiler 
plate construction by riveting is approximately 
75% greater than in the case of the welded con- 
struction. 

The amount of power required fur riveting is 
double the amount required for welding. The 
investment required by the arc welding appara- 






Fig. 78. Annealing Pot made with the Electric Arc Welde 




Fig 79 Storage tank made complete bj elect rii arc welding. 

The flanged end is welded into the sides by melting its edges 

tog« thei « ith ill-- < dgi - of the side sheets 




* 



/*?< 



'* .*> k« v j 



■»•»»<»■»> 



■I 



I ig\ 80. This conical sheet was welded at the point shown, in 

order to avoid a double lap at the edge of tin work which 

would have been difficult to rivet 




Fig. 81. Cylindrical Tank in process of welding, Tins shows 

an ingenious method of mounting the tank on a "horse" and 

clamping the. edges of the sheets by m ans of two plates secured 

together by bolts. 



35 




iL. i unit!] 



iiiimiiiiiiiiiiiiiiiiimimiimiiiiiiiiiinii 



ELECTRIC ARC WELDING 



mini nun ii 



i - < i ■ ■■ .. -., l a ck nf i 



b^^4r 



h &*?£ &}£ 




</ 



V 




■ 




v. 5m 



1 1 S uga 1 l ' 

-< am- and i 

t ombination 

md ex] 



lilei apparatus. This 

. ■ ample 
with riveting. Wt 
ensh c Banging work. 



tus is somewhat higher than in case of the rivet- 
ing machinery, but this of course is offsel b) the 

lower operating" cost, 

Strength of Weld 

The above analysis has been made with refer- 
ence tn jobs which can be either riveted or welded 
and it shows rather conclusively that it is con- 
siderably mi ne expensive to rivet a joint than 
it is to weld it. 

The strength and durability of the welded joint 
is greater than the same properties of the riveted 
joint in the ease analyzed above. The welded 
joint ma\ be lOOjt efficient or as strong as the 
original plate which is a strength impossible in a 
i n eted ji lint. 

In addition to the actual work outlined above, 
reinforcing of boiler plate with steel angles offers 
a further opportunity for the arc. 

Frequently a vessel must be manufactured in 
which one of the plate- is larger than any of the 
standard sizes of plate. Two plates can then 
he butt w elded t< igether for this purpose ; this has 
been done with perfect satisfaction in a number 
ises in strainers, driers, water heater-, etc. 

In the substitution of the welded joint for the 
riveted joint, it is recommended that in plate of 
,■;, inch in thickness and over, wherever possible 
a joint be made as a lap joint rather than a butt 
joint. The amount of lapping should be at least 
four times the thickness of the plate. The work 
can be held together preparatory to welding by 
the use of hults and after the job is welded the 
bolt holes can be filled up and chipped off. The 
use of a hammer for the purpose of hammering 
the metal welded on after the weld is completed 




Kig. 85. Section of smoke-stack made by the New York Edison 
Company by electric arc welding. 



36 



BOILER PLATE WELDING 




in order to "pack the metal in" should be dis- 
couraged . This is of no benefit and a positive 
harm may come to the metal from this practice. 
The chipping tool can be used, however, to dress 
the welded joint up to make it neat in appear- 
and'. In case the welded joint is to be subjected 
to a pressure test and it is found that there are 
small pin hole leaks, these leaks can be satisfac- 
torily repaired either by chipping out a small 
amount of metal at that joint and filling' in new 
metal or by a small amount of peening with a 
center punch at the point at which the leak 
' iccurs. 

Where heavy plate is being welded and more 
than one layer of metal is put into the joint the 
operator should always be required to brush the 
thick layer of oxide from the metal with a stiff 
brush commonly known as a casting brush or a 
painter's wire brush. This is done so that the 
metal throughout the whole weld will be as free 
from slag and oxide as possible. Neglect of 
this important practice may mean a leaking or 
spongy weld. On pressure tank work where a 
homogeneous weld free from blow holes 1 1 - an 
absolute necessity, the operator should hold as 
close an arc as possible and the speed of the 
work should be sacrificed in order to use a com- 
paratively low current and consequently get the 
metal into the weld in the best possible condition. 

Most of the welding in boiler shops should be 
done with the metal electrode, although on vcr\ 
heavv plate above ^-inch the carbon arc may 
be used to speed up the operation. 

With the metal electrode 150 amperes current 
for each operator represents the capacity re- 
quired in the welding machine. In the general 
practice of the boiler shop, the majority of the 
work would be done with y^-inch metal electrode 
and 150 to 175 amperes current. 

Equipment 

A discussion of the various types of equipment 
available for boiler shop work will be found on 
pages 50-57. 




I ig 86. Part of "heater" made by electric arc welding a dish 
shaped steel head into a cylindrical shell and welding in piece 

of pipe. Heads are made of ', inch plate, and the cylinder is 
' s inch material. The cost of tins operation was 50c per head 
'., i . welding, against $1.50 per llead by tin- acetylene process 
Pressure test of 1800 pounds per square inch did not show the 
slightest sign of leakage or failure. 




.57 



Fig. 87. Lincoln Arc Welder in the plant 
Oil Co., Cleveland, Ohio. 



if The Standard 




iiiiiiiumi iiniim inn 



.1 ... ■ ■ ii 



■ 



ELECTRIC ARC WELDING 



i ■■ ■ ""ni'iiiii i 



nun ii ».■■ Hi' ■ 



Electric Railroads and Shops 




The use of electric arc welding on the electric 
railroad is divided into two distinct classes oi 
w ork 

1 Track Repairs. 

_' Repairing broken or worn equipment. 



Track Repairs 



The welding on track work consist oi the 

filling of cupped joints, tin- repair <>i switches 

ami hard centers at cross-overs, reclaiming worn 

joint plates, building compromise joints, cutting 

orn -<■. : i> ins, cutting ■ iff bi 'lis. 






-v r 



Cupped J units 







Fig. 89. Guard for trai 
Welder I his was foi 
dotted lines in the ski ■■ 




^J' 




V 



Cupi 






^^5***— • 







The necessity for repairing a joint b\ the 
process arises from the fact that on track where 
the cars pass in one direction only the wheels, in 
from one rail to the adjacent rail, pound 
nut a cup mi the second rail. This comes about 
as a result of a breaking down of the road bed 
which makes the joint rest on an insecure f 
dation. The constant pounding loosens the bolts 
which hold the fish plates so that in time the jar 
in passing from one rail to the next becomes 
noticeable to passengers. Once such a cup has 
been formed there are only two way- in which 
the difficulty can he eliminated; either the rail 
..in be taken uin and a new rail put in. or it can 
In- repaired 1>\ the arc process. The former 
method cannot always he used, because it' the 
i rack i- ill bad condition ami all of the rails are 
pretty well worn, the introduction of a new rail. 
which is mil worn, will make conditions a- bad 
a- they were before. The usual procedure where 
the arc process is nut used, is to take up all of 
the track where the trouble occurs and relax 
rails Tlie expense of doing tin-, of course, is 
very high 

Then Lre man) cases on reci >nl where 
line- (if track have been kept m service by the 
use of the arc welder fur three or four years in 
addition to the ordinary life of the track. The 
saving in cases of this kind runs into thousands 
of dollars and the cost of the equipment is a 
negligible fact' r. 



Corrugated Rail 



I ig 91 



; built up b> 

stood 1 1 



Another defect which occurs mi the electric- 
railway track is known as corrugation. The 
causes assigned for this difficulty are numerous. 



38 



inn it iiinmiii!! i 



iiiimiiiiiiiiiiiiiiiiiiiiiiiiiiiimiiiiiimiimiiiiiimiiiimimii 



....I. MMI I... I Mill It 1:1111111111111. ,i 



STREET RAILWAY WELDING 



iililililiiliiiiliiiliiiiiiiiiminiiijiiiiimii "i:'i::iiiimiiiiiiimiimmiimi 



but the corrugated rail looks as if the metal on 
the top of the rail had Keen slipped into cor- 
rugations. A car passing over a corrugated rail 
makes considerably more noise than when passing 
over a perfect rail and a distinct vibration and 
jar is felt by the passengers. < )nce a rail begins 
to show corrugation, the deterioration is rapid. 
In the case of corrugated rails and cupped joints, 
the metal electrode process is used to fill in the 
low spots. After the metal has been filled in 
the excessively high spots may be ground off 
with a grinder. 




Grind i /is* 



There is some variation in the practice oi 
grinding off the excess metal. Some companies 
use the reciprocating grinder only, while others 
use both the hand grinder and the reciprocating 
grinder. The latter process seems to be prefer- 
able because it is undoubtedly the most eco- 
nomical. The rate of grinding with a hand 
grimier is rather low, and where the filled in sec- 
tion is considerably higher than necessary, an 
unreasonable length of time is required to bring 
it down to the proper surface. 



Coin promise Joints 

Where "T" rail section joins girder rail a 

compromise joint can lie made getting a g 1 

body of steel at the rail ends by building up with 
the electric arc. 



Electrodes 



The kind of electrode used depends a great 
deal upon the work. So far as actual resultsgo, 
the basic steel electrode or even Swedish iron 
will give results which are entirely satisfactory 
on ordinary rail section. The ordinary rail sec- 
tion may contain as much as .-Ml',' carbon while 
the basic steel electrode usually does not contain 
any more than .12',.' carbon. It would seem 
that the metal in the welded section therefore. 
would be considerably softer than the rail. This 
however, does not seem to be the case 

The cast steel which is put on the rail by die 
metal electrode process is not a normal cast steel 
due to the oxidation and sudden cooling at the 
instant it is deposited on the rail. It has been 
found that by forging metal so deposited, or in 
other words giving it a mechanical treatment, 
when cold, increases its hardness to a consider- 
able degree, so that after the repaired rail has 



Lincoln Arc Welder mounted 
repaii si n ice 




iu 93. Truck Side Frame repaired by Electric Arc Welding. 
Breaks in the- frami 01 worn boll holes can he repaired m this 
way. The holes are till..! in with new material then re-drilled. 




Fig, 94. A badly worn armature shaft h 
n c w elder. This i-. aftenvai ds mai hined 



ilt up with 
[own to pro 



electric 

ri Size. 




Broken parts <>f truck frame repaired by arc weMiti] 



3') 



L 



iHiiiiriiiiiiiiiiiniii mil ■ 

ELECTRIC ARC WELDING 



i mm 



"mm 'mini 




liiltn' 

pei bar, •■ 




. 








Fig. 99. This worn gear case was repaired by using a dis- 

et car gong, and welding it over the portion of th< 

fhe case was made as good as new at a cost of about 4?c. 



been in service fur a short time, the action of the 
wheels in giving the metal this mechanical treat- 
ment probably renders the metal considerably 

er than the metal of the original rail. For 
high carbon rails, that is rails which contain as 
high as .90% carbon, and for manganese center 
special work the special slag coated electrode 
should be used. < Ine street railway company buys 
ordinary spring steel for this purpose which pos- 
sesses about 1',' carbon. The results they obtain 
b) the use of this steel on manganese center and 
high carbon rails are perfectly satisfactory. The 
building up of broken tongues in switch con- 
struction is also a frequent application. The 

— metal here, of course, is ground "ft' bv 
tin- use i if the hand grin 



Shop Welding 

The application of arc welding in the electric 

railway repair shop has not proceeded with the 

same rapidity as the application on track work 

has proceeded, although the saving which can be 

nplished is quite as great. 

The operation of electric car- over the track 
produces excessive wear on practically every part 
of the truck and under-framing. The wear and 
tear on electric car- i- probabl) greater in pro- 
portion to the value of the equipment than is the 

wear On a -team I . c, resulting from it- 

travel over the rails The sudden starting and 
ping with the consequent reversal of -trains 
in all the members, mean- that at every point 
where the car is fastened together with rivets 
:r occurs. Where one part 
rubs over another, the deterioration i- extremely 
rapid. When a part becomes worn there are 
only two things that can be done; either new 
metal can be added and the part repaired, or it 
must be scrapped and a new part put on the car. 
!t is obvious that the repair of the part by adding 
new metal produces a large saving. 

Where a part can be repaired without taking 
ar apart or taking the truck out from under 
the car. by the use of the welding process, an 
additional saving is made. Owing to the ease of 
application of the arc process, this can frequently 
be done and in this case the Master Mechanic 
can credit himself with saving the price of a new 
part, le-s the cost of welding — the saving in labor 
represented by the amount of time saved by not 
taking the car apart, and the additional saving 



4- 



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iiiiEimiiiL :: . niiimiiiiiiiiimiiiin 



STREET RAILWAY SHOPS 



resulting from keeping the car in service rather 
than having it lying idle in the repair shop. 

The following parts are some of the principal 
cue-, which are repaired : 



Truck frames 
1 )raxv heads 
Brake hangers 
Spring hangers 
Body bolsters 
Gear cases 



Armature shaft 

Gears 

Journal boxes 

Resistance grids 

Truck bolsters 

Channel iron underframins 



Arc Welding vs. Oxy-Aceytlene 

The only way in which the metal can be filled 
in the worn parts is by the oxy-acetylene welding 
process, or by the arc process. The relative cost 
of the two processes is much the same as in 
other applications. The cost of operating an 
oxy-acetylene torch for repair work of this na- 
varies from 60 cents to $1.50 per hour. An aver- 
age cost of operation per hour is probably in the 
neighborhood of $1.00. This takes into account 
a considerable amount of preheating on steel 
work by the use of kerosene torch of a preheat- 
ing furnace. Without the preheating arrange- 
ment the average cost per hour of operating the 
torch is probably in the neighborhood of SI. 50 
per hour. The following table shows some com- 
parative costs on typical miscellaneous jobs en- 
countered in an electric railway repair shop. 

Cost Based on Conditions of 1916 



Descriptii ■ Cost of 

:>t Job Replace ment 

Bearing Housing 
made of cast steel. 
Repair job $ 8.60 

Axle cap. Renewing 

dowel pin holes. . 11.15 

Repairing Armature 
shaft, pinion seats 
and Key way 55.00 

Journal boxes re- 
paired by use of 

chafing plate .... 6.90 

Truck Frame 60.00 

Resistance grids. 

Typical repair job 3.00 

Reducing bore of 
gear. This job 
impractical with 
oxy-actelyene. Re- 
duction too small 
for use of bushing 30.00 



Cost 




Oxy Acety- 


Cost Electric 


ls nt- Torch 


\n Welding 


£2 60 


$ .75 


70 


.25 



7.20 
.80 

3:00 



1.75 

.20 
1.10 

.20 





4.10 



Fig. 100. Miscellaneous repair jobs on street railway work 
maile with the Lincoln Arc Welder by The Harrisburg Rail- 
ways Co.. Harrisburg, Pa. 



The metals encountered in the repair of cars 
include cast steel, cast iron, wrought iron, and 
mild steel. All of these metals can be success- 
fully handled in the railway repair shop. A large 
percentage of the work can be "bench work" 
and preheating furnaces and torches can be used 
to a good advantage. 

There is one peculiarity to the application ot 
the process for the repair of cars that does not 
exist on many other arc welding applications. 
There are many jobs of exactly the same nature 
since the car equipment is standardized to a 
large extent. This justifies a considerable amount 
of time spent in the solution of a given problem 
since that it is certain that a number of similar 
jobs will re-occur from day to day. 

The capacity of the equipment required for 
each operator is 200 to 300 amperes. This per- 
mits the use of the machine for either carbon 
or metal electrode on any kind of a job that will 
arise. There are few cases where it would be 
necessary to couple two of the units together to 
get a higher capacity. 

Equipment for Arc Welding 

Complete description of arc welding equip- 
ment for use on Electric Railroads will he found 
on page 57. 



41 



wt 



. 111 : : . 



ELECTRIC ARC WELDING 



Drop Forge Shops 



bv R. I'". Kinkead, before \n 



1 







101 R 



The arc welding process is being used sue 
fully a) the present tunc in the repair ol de 
in drop forgings before the forging leaves the 
shop. Tin- work is done to improve the ap] 
ance of the forging rather than in improve its 
strength, although the correction of certain de 

ili ics increase the strength i if the pii 
I he must important class of forgings which 
quire the correction of small defects is aut 
bile forgings The defect- corrected are low 
spots, parts not properly filled out, an 
kinds of o >1<I shuts. 

The defect is simply filled in by the metal elec 
trode process and the excess metal ground ofl 
with an emery wheel. It is not often i 
to re-anneal the forging after the welding proc- 
ess owing ti> the very great localization of the 
heat, although if the piece is annealed after weld 
ing, the pi lint at \\ hich the o n 1 1 ■■. as made 

cannot be located. The work can be done very 
rapidly owing to tin fact that the instant the 
operator strikes the arc. he can start filling in 
the metal. \*o preheating is necessary. The 
lowest priced man in the shop can do the weld 
ing. 

The designation of the forgings to be o n re< ted 
by welding should be dune by a competent fore- 
man or the superintendent of the shop. Know- 
ing that the metal to be added will have a certain 
tensile strength and ability to resist shearing 
stress and that it will have a very small degree 
of elasticity due to the fact that it is cast steel, 



there is little room for difference of opinion as 

to where to apply the welding process. fhe 

on the forging at which the defect occurs, 

has an important bearing on the question of 

whether or not it can he corrected. The service 

ected of a forging also affects the application 

of the welding process. It is evident that a defect 

of certain dimensions can be corrected if it 

occurs on an automobile lamp bracket which 

ould not be safelv corrected if it occurred on 

cvlindei crank shaft The fun-man of the 

shop, or the superintendent knows what to weld, 

it should not be left to the welding operator. 

■since there are only two welding proo 
applicable to the correction oi flaws in drop t 
ings, electric arc and oxy acetylene, a comparison 
may be interesting. The cost of producing a 
unit of heat by the gas process is approximately 
six times the cost of producing a unit of heat 
b\ the arc process I Kving to the great loi ili 
tion of the heat in the arc process, approximately 
three times the welding can be done with a given 
amount of heat as can be done with the same 
tint of heat produced by the gas process. l', v 
actual test, the co t of gas for general work on 
automobile front axles runs from twenty i M 
twenty-five times the cost of electric power to 
dn the same work. < )ne operator with the elec 
trie- arc can do at least twice as much work in a 
da\ as an oxv-acetylene operator. 

The advantage has been claimed for the oxy 
icetvlene process that it enables the operator to 
hum down to the bottom of a cold shut and thus 
till in the whole defect. This practice is also 
possible using the carbon arc process, but the 
practice is dangerous. A forging which shows 
evidence of having a deep cold shut in a part 
ected to heavy stress should not be welded. 
\ forging which has .1 cold shut which will not 
materially affect the usefulness of the forging 
will actually be in poorer condition after the 
defect has been burned out and filled in than if 
the defect were not corrected tit all. The appli- 
cation of the gas flame in such a case will over 
heat a large amount of metal around the •!- 
while the burning out is being done. After the 
irea is sufficiently burned out. a comparatively 
large amount of cast metal will be filled in which 
is known to be inferior to the metal of the orig- 
inal forging. There is no heat treatment which 
will bring the forging hack to a condition equal 



42 



mil iii|i;iiillliili[i!llill:!|||ii!lllllii 



iiiitiiiiiiiiiiiiiiiiiiiiiiiniii i i /mi.- mi .' i i iin i ' ' ' ■■ '. mi minimi 



iiniiiiimiiiiiiiiiiiiiiiiiiiiiiii 



DROP FORGE SHOPS 



" minium iiiiiiiiiiiiii 



i II mi minium 




I.. its condition before the welding was done. 
It is much better to simply till the defect in a 
depth uf approximately a sixteenth of an inch 
with the metal electrode process which will nut 
materially affect the metal surrounding the 
defect 

Overheating the metal in a drop forging is 
always undesirable, particularly in the case of 
the allo-\ steels used fur certain automobile drop 
forgings. The high temperature reached in the 
gas flame and the electric arc affect the structure 
uf the steel to such an extent that it can never 
he made identical to the structure which has not 
been affected by the welding process. It i- evi- 
dent therefore, that the heat used fur welding 
should he localized as much as possible. The 
oxy-acetylene flame will heat from three to five 
time- the volume of metal in performing a given 
welding operation that will be heated when the 
arc process is used. The arc produces heat in 
the metal at exactly the point where it i- needed, 
while the gas flame produces the heat external to 
the metal ami blows it over a large area 

The welding uf defects on drop forgings is a 
delicate matter among some manufacturers at 
the present time. This condition of affairs 
appear- In he <\uv to the fact that the process 



is new rather than that it is immoral. When 
the -teel foundries first started to correcting de- 
fects in important locomotive castings there was 
the same feeling prevalent. In tact must uf the 
welding was done in the dead uf night and behind 
carefully guarded doors, 'fin's was only five or 
six years ago. \'<>w practically every steel foun- 
dry has one or more arc welders, and every kind 
of a steel casting is welded in the presence of 
the inspectors. Defects in gun carriages fur the 
Yaw Department are corrected in and out uf 
the Navy Yards. 

The responsibility fur a drop forging rests 
with the manufacturer. If he can make forgings 
at a price at which they can be sold at a profit 
and the forgings stand the service he can stay- 
in business. If the manufacturer sends out bad 
forgings, he loses his business. As long as a 
manufacturer must scrap forgings with insignifi- 
cant defects on them which his competitor can 
save, his price on the product will be high or his 
profit low. The present tendency uf prices of 
automobiles dues nut permit the quotation of 
fancy prices on drop forgings. The welding of 
small defects on drop forgings therefore is a 
matter of business economics, and will undoubt- 
edly lie solved in exactly the same manner as it 
has been solved in the case of the steel foundries. 




I 




t *w. 



:&*U 



^^fewi n " 




l'u; 102, Lincoln Arc Wi 



i gi Drop Forging plant. 



43 



ii 






ilillililiiiiiiiiiiiiiiiiiimiiiimiilllllliiiii 



i! .i.ii! ii iinii'. in dliiilli iiiniiiiiiiii 



ELECTRIC ARC WELDING 



III!; ■ ::■---- I ■ 1 1 1 ■ ■ s - -S ■ I ■ I r 



i i iwiii i w mil ■ ii ■ IIIIIIIIIIHIII 



Commercial or Job Welding 



'9 ' 




.<£ 


Wf 


a- ■ 


1 



Every city of am size has a number of small 
shops where welding of all sorts is done. 

For a long time acetyleiu weldin 
chief process in use in these shops. l"he\ were 
started, mostly, b\ men who had done acetvlene 
welding in various manufacturing plants until 
the) had become very expert in its application to 
all sorts of work. 

< > 1 1 starting business for themselves, they nat- 
urally adopted the process with which they were 
familiar. They were prompted not only by this, 
but by the fact that it required only a very small 
capital to buy the necessary equipment for acety- 
lene welding. 

fhese early shops have grown in number and 
have increased in size remarkably in the past 
ten years. Hie larger ones have now come to 
the point where there is a continuous stream of 
work passing through their plants and they have 
been obliged to look very carefully into methods 
of reducing production cost. ( ompetition has 
grown keen in proportion to the success which 
the early shops made of their business. 

' Iwing to tin- condition, main- of the shops 
have carefully investigated and have been [Hit- 
ting in arc welding apparatus t<i take care of 
a great deal oi their work. An investigation lias 
shown thai from 30 to 60 per cent of the work 
which is welded b\ oxy-acetylene can be done 
equalh well with the arc process, and what is 
nil. re important, it can be done usually for less 
than half the cost of acetylene work. 

There are undoubtedly case- in which oxy- 
acetylene must lie used in preference to the arc. 



such as the case of welding automobile cylinders, 
but this class of jobs form only a small percent- 
age of the work done by a large commercial 
plant. Many such plants employ ten to fifteen 
operators and in a plant of this size, there is 
always work enough to keep two or three arc 
welding operators busy using the arc. 

Comparative Costs 

The tables given on page 6 are authentic, and 
will give the commercial welder a basis on which 
an compare his present costs with tho 

arc welding. 

The importance of doing this work at the 
lowest possible cost need not be emphasized for 
every welder knows that every cent he saves on 
any given welding job goes into his pockel 
that much extra profit or in other cases it enables 
him to bid lower on desirable work and secure 
it at a good profit against competition from 
-mallei- shops who are figuring work fi r acet) 
'cue welding. 

I lie best possible basis for comparison is the 
actual installation of an arc welding outfit in 
ommercial shop and a thorough trial cover- 
ing a period of two or three months' time. This 
sort of a trial can be arranged at a slight expense 
and ha- proven a means of cost cutting to com- 
mercial weldin- shops in Detroit, Pittsburgh, 
Providence, R. I.. Cleveland, and other places 

where it has been tried 

Portable Outfits 

i ine -..nice of profit to the commercial shop 
is that class of work which cannot be brought 
to the welder, but which operators must go out 
:. . do. For tin- purpose the Pi irtable Arc \\ eld 
ing ( lutlits are made which can be operated con- 
veniently and at very low cost. 

Equipment 

The commercial welding shop needs a welder 
of at least 200 amperes capacity. This will be 
suitable for any metal electrode work or light 
carb. .n electn ide welding. 

Two or more 150 ampere welder- are of 
course to be preferred to one of 200 ampere out- 
fit, as this will allow a larger number of opera 
tors to work at the same time. 

Illustration and complete description of weld- 
ing equipment suited for commercial work will 
be found on pages 50-57. 



44 



GENERAL MANUFACTURING 




General Manufacturing 



The use of welding in repair work lias per- 
haps been over emphasized by all manufacturers 
of welding apparatus. Opportunities for this 
work are most easily found and it is verv easy 
to demonstrate the saving made. 

The field for this class of work does not com- 
pare, however, with the field for general manu- 
facturing work, where welding can be used to 
take the place of riveting and other methods 
of joining metal parts. 

There are hundreds of such applications of 
welding now being made. In these cases the 
work has either been accidentally discovered by 
the manufacturer himself, or some welding engi- 
neer has carefully sought out this application 
and demonstrated it to the manufacturer. 

Tt is exceedingly difficult to obtain data or 
photographs on this class of work. The manu- 
facturer who has successfully applied it, is nat- 
urally averse to giving out the fact, since he is 
usually making savings which are important to 
him in meeting competition. Strictest secrecy 
is often maintained regarding this work. 

Each manufacturer is therefore obliged to find 
his own application for arc welding to a great 
extent. 

We have endeavored to present on page 49 cer- 
tain typical illustrations which show not any par- 
ticular manufacturing process, but the genera! 
application of welding so that each manufacturer 
can apply the principles shown in these samples 
to bis own particular problem. 




Fig. 103. Laminations for magnetos and electric starting appa- 
ratus welded together by electric arc welder, eliminating two 
rivets and preventing the laminations from spreading. 




Fig. 104 Welding steel sheets together to form gear ca^es The 

Insrs on the inside rf tl'< ca e an also welded on Jobs -imilar 

tu this can In- found in hundreds of manufacturing plants 




iing replaces brazing and save? itioiie; on 
-I,: I automobile t'i ames, 




Fig 106 \ bolster made by welding together 3 16 inch steel 

plate. The holes in the side of the bolster were also made by 

the arc welder and afterwards smoothed up. 




Fig. 107. BEFORE GRIND 

ING. Steel Wheel made by 

welding a steel plate rim and 

bolting it to steel spokes. 



AFTER GRINDING. Steel 

Wheel after the weld in the 

rim had been ground down to 

give smooth surface 



45 



II ■ ■ II ■ 



. i . mi mini miiiii in . ■ ;.:. mil : n mi i n inn! I mini n 




in;, i i .in. '. ii 



ELECTRIC ARC WELDINC 



ii' ninn m ni ■ mil 











Sheet and Plate Welding 

II i < • application of welding to this class of 
material lias been covered in boiler plate work. 
The range oi work is so wide here that there is 
no possibility of giving definite rules covering 
the subject. The best that ran be done is define 
the limits within which welding can be succi s 
full) perfi irined i m sheel - and plates. 

< ienerally speaking, arc welding cannoi be sue 
Fully applied to steel sheets ni less than 20 
gauge In certain instances where sheets are 
welded to reinforced angles or are backed up 
h\ some heavier material, it i- possible \>< weld 
thinner material successfully. 

Reinforcing of sheets or plates by angles, rims, 

presents another possibility fot arc welding. 

It has been successfully applied fur welding angle 

supports on tank wagons, reinforcing rims 

in large storage tanks and other worl< of this 

general nature. 



Pipe Welding 



The advantages of welding for pipe construc- 
tion have been a subject of careful investigation 
by The Xational lube Co., ami others interested 
in this sub 

It has been found that welding gives a more 
permanent joint in pipe than the couplings ordi 
narily used, that n gives a strength equal to that 
of the solid pipe and reduces the tendency to 
leakage at joints by eliminating couplings, the 
whole being practically one unbroken length of 
pipe. 




_ 



sen 5 made I 

i] shaft. 



: steel 




Fig 111. Welding door hang* I firepi tee] doors. The 

square tubes on the horse arc also arc welded on the -..tin-. 



-!.i 



liiimmiiiimiiiMiiii. "i .mm nin :imi ■ i 



mi i inn in inn 



in mi i . . ; mi 






GENERAL MANUFACTURING 



These advantages are of special importance in 
the construction of superheaters and similar ma- 
terial made from pipe products. An especially 
good instance of superheater welding is illus- 
trated. 

A development of this process is the welding of 
flues in locomotive boilers which has been very 
widely practiced in railroad shops and locomo- 
tive manufacturing plants. 

It is the present theory that welded pipe lines 
reduces electrolytic action and corrosion. The 
welded pipe presents a continuous conductor in 
which the resistance is lower than in coupling 
pipe thus reducing the tendency of the current 
to jump joints and set up electrolytic action. 

This use of welding is applicable not only in 
shop manufacturing work, but in laying of pipe 
lines and can be taken care of to good advantage 
by a portable arc welding set, which either takes 
current from the trolley or electric supply line. 
A Portable Welding set, driven by a gasoline 
engine or mounted on a truck and driven by a 
truck engine will accomplish the same result. 




$*--■■- 



Kig. 11? Lincoln Arc Welders in the plant of The Standard 
I'nrts Co., large manufacturers of automobile parts. 




Fig. 113. Steam Superheater. Every joint made by electric arc 
welding. 




manufactured 



Lincoln Arc Welder. 



47 






Hilliiillllliiilllllillillim .inn. miiiiiiiiiiiiuniiii ' .:,;.. .::. i mini miiimillllmiiiiini 

ELECTRIC ARC WELDING 



mi ■■ 




Repairs 



Repair 




Fig. USA. 




1 ig 117, I incoln Arc Welder in plant of Aultman & Tayloi 
M Co., Mansfield, Ohio, used foi general manui 

and repair work on agricultural implemi 



Ilk' repair oi defects in manufactured pieces 
has already been discussed under the subject of 
steel castings and forgings, where arc welding 
lias thus far bad its greatesl application. 

There is undoubtedly another wide field in 

building up of pressed metal parts which come 

mperfeel from the dies and which have cracks, 

"short sides" or similar minor defects, which 

could be readily repaired b) adding new metal. 

The repair of broken machinery or parts can 
be made quickly and at low cost b) the arc weld 
ing process. Unless the plant is a large one and 
would have a considerable amount of this work, 
acetylene would be cheaper than arc welding, but 
where there is enough such work to keep an 
operator busy a great portion of the time, the 
arc welding would be found most economical. 

The general nature of such repair work, fol- 
lows under several headings. Rolt holes often 
become worn and necessitate replacing the worn 
puce with a new casting. This can be avoided 
by filling the worn hole with new metal then 
redrilling it. Bearing surfaces on slides, cams, 
eti . are repaired by somewhat similar processes. 
Patches are applied on ladles, tanks, and ve 
used in different manufacturing processes. 

Steel mills have found it economical to install 
arc welders for the purpose of repairing wobbler 
in the rolling mill. The ends of these wobblers 
are built up with new steel to original shape, sav- 
ing the cost of a new roll casting, which is much 
i expensive than the ordinary casting steel. 
Work is also being done successfully on the 
w i irking surface of the roll. 

Steel shafts are built Up ill somewhat the same 
manner, new material being welded on to the 
worn end, and the shaft then being put into the 
lathe and then turned d' >w n. 




Fig us. Steel parts incorrectl) machined built up 1> the aic 
weldei and ifterwards re-machined to pi pi 



48 



iiiiiiiimiiirminmi:ii ..:. , mi 



illllimilllliilllliiiilliiim niiilliilili 



, i) i. ii in minim is ■. 



ELECTRIC ARC WELDING 




Suggestive Applications 





Fig. 118A. FLUE WELDING 2" Flue 
Locomotive Back Flue Sheet. Actual Time: 
2 minutts 2" Flu..-; 7 minutes 5" Flui 
Electrode 2" Flue— V— 00-100 Amp. 5" 
Flue — 5/32" — 120-130 Amp. The total 
time U) weld a complete set of flues de- 
pends on the condition of the flues and 
flue sheet. A fair average may he calcu- 
lated from the above figures by adding 
50% to the total time for rest periods. 



Fig ] 1811. FLUE WELDING 1. Pul flue in as 
it" ii were nol to be welded. 2 Send the engine 
out fnr a few trips to lit the tubes take their set. 
::. Sand blast the flue sheet. 4. Weld flues A 
heavj bead of welded metal around the flue is nm 
. ,i put on the smallest bead that can be 

thorough!? welded to both flue and sheet 






Fig. 118D FLANGED HEAD 
BACKED INTO SHELL. 



ill I LANGED HEADS- 
BOILER PLATE. 



%" Plate— Speed— 7 Ft, per hour. 5/32" Electrode L30 Amperes. Fnr 
High Pressure, joints should be welded inside and out. 





Kig. use. PIPE wi LDING See "Build- 
ing I'ji Operation" for speed of work. The 
Welded ioint is stronger than the threaded 
iotnt. Steel or wrought iron pipe onls mas 
be welded. 




i:uILi;n PLATE 
Si i 
p ( i T 1 r Electrode 



*%" 

Ahoy. 
only, 



no Amps 
120 Amps. 
150 Amps 



6 %-3/16 

Bgures include straight welding time 
Loss of time in handling the job must 
taken into account on each job. Vertical 
<>r overhead welding speeds are at least 50% 
l>elow speeds given above. 

-V wire Is used to fill in bottom of seam. 



1 ig ] 18.1 WELDING IN PLACE 01 

CALKING speed of work depends on 
amount of metal added. Strength of joint 
may be raised 25 doing the work at three 
times the welding speed given in table, 
page 6, for any thickness plate above *4". 
This makes a single riveted joint equivalent 
to a double riveted joint and makes a 
double riveted ioint as strong as the 
original plate. Joints welded in this man- 
ner stand nun-It abuse without leaking. 



49 



Fig. 118K. BUILDING UP OPER VTIONS (Note 
that the weld Is oasil) machined! 5 32" Electrode, 1 10 
Amp.. 20 Volts will deposit one pound of metal in ap- 
proximately 30 minutes. 3/16" Electrode, 1T5 Amp., 22 
Volts will deposit one pound of metal in approximately 
20 minutes I ' ' Electrode, one cubic inch of 

stool may be deposited In about 7% minutes. The 
metal when deposited on mild steel bj the metal elec- 
trode process will always be sofl and easily machined, 
The carbon electrode process should be used for build- 
ing up operations only when the built up piece can be 
later annealed to take out contraction -.train. 




ii iii mill 



ELECTRIC ARC WELDING 



* * Current for Electric Arc Welding 



The successful commercial use of electric arc 
welding on the scale indicated in this book re- 
quires direct current. Alternating currenl does 
not produce an arc which can be controlled to a 
sufficient degree for such welding. The voltage 
id the current must be from IS to 30 volts 
metal electrode welding and from 30 to 45 volts 
for carbon electrode welding. These voltages 
are lower than are supplied by any power com- 



pany and are lower than those used for almost 
any other manufacturing process. The current 
most universally used in manufacturing estab- 
lishments is alternating current because it is 
easily transmitted and can be produced at lower 
cost. For these reasons electric arc welding al- 
ways demands a special equipment to produce 
suitable direct current at the proper voltage for 
welding. 



Equipment for Electric Arc Welding 



There are several distinct types of electric arc 
welding equipment now manufactured. A thor- 
ough understanding of each of these i, necessary 
before an intelligent application of the process 
can be made. 

Resistance Welder 

When electric arc welding was ti i^t used direct 
current was more common than it is i The 

first welding was done by inserting a heavy re- 
sistance in the regular direct current supply line 
in the shop. This line usualh supplied current 
at 110 to 220 volts. The resistance served to 
cut tin's \ , iltage d< >wn t< < fn >m 15 to 20 v< 'Its, thus 
making it adapted for welding purposes. 

The extra power used in overcoming this 
resistance was of course wasted The saving 
elicited however in repairing steel castings and 
in making repairs in railroad shops was so great 

compared to former methods that the waste of 
electric current was a minor matter. This re- 
sistance was usually made either by passing the 
current through a barrel of water or by passing 
it through a cast iron grid resistance. This 
resistance served two purposes, first to cut down 
the voltage, second to prevent a great rush of 
current when the electrode was first touched to 
the piece to lie welded. 



Motor Generator Sets 

This type of equipment was made necessary 
by the fact that alternating current is now in such 
wide use. Some means had to he devised to 
transform alternating current into direct. In 
the motor generator set a motor is used which 
is arranged to be driven by the electric current 
supplied to the shop. This motor in turn drives 
a generator which delivers direct current for 
welding purpi ises. 

economj of tlii- method over the resist- 
ance method is at once apparent because the cur- 
rent taken from the supply line is not wasted but 
used directly in driving the generator. Even in 
plants where direct current is available, a motor 
generator set is used, the motor, of course, being 
a direct current machine. 

In the gradual refinement of the motor gen- 
erator for welding purposes, two distinct types 
quipment were produced. For want of a 
better term, these have been called constant 
voltage welders and variable voltage welders 

Constant Voltage If ciders 

This type of motor generator set has a gen- 
erator which delivers current at a constant VOlt- 
N'ote; In plants where no electric current at all is available. 
it l- still possible to do welding work by means of a 
generator belted to the engine or line shaft. Such an 
- qui pment is shown mi page 54. 



50 



ARC WELDING EQUIPMENT 



iiiiiiiiniii 




age of about 75 volts. This voltage, however, 
is still too high for welding purposes and has 
to be reduced by introducing a resistance in the 
circuit. The power consumed in this resistance 
is of course wasted just as it was in the old type 
of resistance welder, the only difference is that 
in the constant voltage welder, the waste is con- 
siderably less. 



Variable Voltage Welder 

It should be understood that in arc welding 
the voltage of the current actually used is con- 
tinually changing. For instance, when starting 
the weld, the operator touches the welded piece 
with the electrode, then as the current begins to 
flow, he draws it away a short distance establish- 
ing the arc between the electrode and the welded 
piece. 

At the moment he touches the electrode to the 
piece, the voltage in the circuit is nearly zero 
and as he draws the electrode away, the voltage 
constantly increases as the arc lengthens. 

For this reason, an arc welder cannot be truly 
economical in use of current unless it gives ex- 
actly the right voltage for the work at every 
instant of operation. 

To produce this result a generator has been 
designed which always delivers the exact volt- 
age required at the arc at any particular moment. 
This is the chief characteristic of the Welder 
manufactured by The Lincoln Electric Co., of 
Cleveland, and this principle is responsible for 
the remarkable success this welder has made in 
every field. 

Expert Opinion 

Engineers in industries where welding is 
widely used have made a very thorough investi- 
gation of these two types of welder, realizing 
the importance of choosing the right one for their 
particular work. 

The Railway Mechanical Engineer in an 

editorial in their November. 1916 issue have the 



following to say in reference to these two types 

of equipment : 

"Two distinct types of motor generator sers 
are available for arc welding, different manufac- 
turers championing differenl systems. In one 
type the current is delivered at an approximately 
constant pressure of 75 volts and an adjustable 
resistance is used in series with the arc to vary 
the arc voltage to suit the work in hand. 

"The second type of motor generator set is 
so-called constant current or variable voltage 
equipment. In this system the generator de- 
livers a variable voltage, maintaining an approxi- 
mately constant current flow. Tt is therefore 
effective in affording constancy and uniformity 
of the arc and inasmuch as no ballast resistance 
is required, this system is more efficient than 
the previous one." 

The Association of Railway Electrical En- 
gineers appointed a special committee on the 
subject of arc welding and their report of Octo- 
ber 31, 1916, gives a valuable comparison on 

this point. 

"There are two types of equipment in the 

market which may be described as constant 
voltage type and variable voltage type. 

"The constant voltage type is a motor gen- 
erator set which takes power from the shop 
mains and delivers on the generator end a prac- 
tically constant low voltage. A resistance ballast 
is used between the generator and the welding- 
arc to limit the current at short circuit. The 
power used in the resistance ballast is of 
course wasted. The low voltage direct current 
power is carried over the shop on heavy cable- 
to the welding outlets. 

"The variable voltage type is a motor gener- 
ator set which takes power from the shop mains 
and delivers on the generator end the voltage 
required for welding without the use of re- 
sistance ballast. The inherent characteristic of 
the generator is such that the short circuit is 
limited without the use of resistance ballast. 
Inductive ballast is used to stabilize the arc. This 



51 




ii' i. ■ :i i ■■ mi . iiimm:i nin . 



. mini mi i iiii ■ . . nil 



ELECTRIC ARC WELDING 



ii ;n i 



:, Ill " I 






i\ pe of equipment is made only in single opei 
units. Willi this type of equipment the low 
voltage distribution system may he elimi- 
nated, riie mol • : fed directh from the -Imp 
line? 

Com partitive Costs 

The question again resolves itself hum 01 
the comparative cost of the two types of equip- 
ment, llourh co system can he readily 
figured. 

hor this ] 
ci mdii 

\ . iltage aetuall 

Cost < if cun cut per K. \\ . hi iir . . 

I 'nder these condit ider fii 

• if electi i by the i >ld resistant i 

of welding. Second the cost n 75 volt 

constant voltage motor generator. Hiird the 
cost with a variable voltage 

In using .1 ;enei at< >r set, it is neci 

-nine a J? per cent loss owing to power 
required to run the machine. We then havi 
following figures: 



CUITI til 

Vv, 

] 50 Amp 

1 ; ii Anip 



Kilowatt 

llOUl S pel 

! 



Cost .it 

I'l i \M I 

I |i I 111 HI 

of welding 

7 ; cents 

28 cents 



\ 'i i uli re- 

Motoi gi neratoi - 

\ lilt- I 

Motoi ' Var- 

.V II- 

fi gu res a n on 

■imislv. As a matter of fact it would not 
he usi half of the time I 

the same r< pet ation fai tor. 

Ease of Operation 

I he difference in operation oi the two tvpes 
of machine is equalh a- important as the cost, 
characteristic of the variable voltage welder 
is the ease with which the arc is controlled thus 
preventing the frequent make and break of the 
arc which results in imperfect work. 

\11 complicated switches and solenoids are 
eliminated on this type of apparatus and one 
simple knife switch, together with a small rheo- 
stat handle for regulating the current, is all that 
is necessary. 

Importance of Equipment 

I lu- selection of the right equipment for arc 
welding work is of the utmost importance. The 
consideration given to the subject b\ the two 
authorities quoted above indicates this. 

Both the results obtained and the cost of op- 
eration depend entirely upon the type of equip- 
ment selected. 



52 



LINCOLN ARC WELDERS 



i»i "in" mi mi ii ■ iiiiii mini i ii i ■ ii 



tiiiimiiiiiiiiiiiimiiimit iiiiii n Minimum 



liiiimiiiiiiiiniii in i 





I ig I 19. Line 
nating ( hi rent 
i Weld, i foi 



In Arc Welde 
Suppl} . This i 

Ik a\ \ stei 1 f. 



for Alter- 

a 400 \ui 

indn work 



1 1 I h \ 




Control Panel 



Lincoln Arc Welders 



The Lincoln Electric Co. have been engaged 
in the manufacture of arc welding apparatus 
ever since its first successful application in this 
country. Welders manufactured by this Com- 
pany, at that time, are still in daily use in spite 
of the improvements effected by the long study 
of the subject. 

Lincoln engineers are not only thoroughly 
familiar with the proper design and construction 
of welding equipment, but what is more impor- 
tant to the prospective user, they are skilled in 
the application of the work in every field where 
it has been used. 

Variable Voltage Equipment 

The Lincoln Arc Welder is a variable voltage 
equipment — the type referred to by the Railway 
Electrical Engineers Association in their report, 
part of which is reproduced on page 51. 



This welder will do welding work at lower 
cost than any other method or process. This 
assertion The Lincoln Electric Co. are ready to 
pmve by direct comparative test on any class 
of work. 

Simple 

Examination of the illustration itself is suffi- 
cient to convince any prospective buyer of the 
simplicity of Lincoln equipment. There is an 
entire absence of the complicated clapper 
switches, solenoids, circuit breakers and other 
devices, which add to the cost and which are 
bound to require considerable expert attention. 

Reliable 

The reliability of Lincoln equipment is di- 
rectly due to its simple construction and to the 
high grade materials used. 



S3 




■ ■ Him in .i mini' in n : mini i . : m n 






i X 



LINCOLN ARC WELDERS 



■ nun mum 



mi i i Miinii mil linn i mmii n li miiiuiiililllllim Ill 



■ Su ppl y 






fi; 



I li 8 



Fig. 121. Lincoln Arc 

Weldei 1""' Vlti i nal 

Cm rent Supplj 



it j 




i ■ 



Individual I nits 

The standard Lincoln Welder is intended to 
supply current for one operator only. The ad- 
vantages of this plan are obvious. The user of 
arc welding can in this way begin with the small- 
est possible initial investment and can add to it 
whenever he requires and in any amount to suit 
his needs. The investment is always propor- 
tional to the aim mnt of work done. 

Another advantage of this arrangement is that 
it allows each operator to be independent of 
the others and to use current only when he is 
engaged in actual welding work. In case of 
trouble with the welding plant, only one man 
would be affected. 

Adjustable for Heavy Work 

In most cases, the single unit is amply large 
for any work that occurs. In large steel foun- 
dries or railroad simps, where an occasional large 
job of carbon electrode welding is necessary. 
two or more Lincoln Welders can be connected 
in parallel to do the work, furnishing ample 
power for any welding purpose whatever. This 
connection can be made in five minutes' time 
by any welding operator and the plants can be 
separated again with even le-.s work. 





" liM 



'^?s* 



Stabiliz 



C .mi il 



i icne rato i 



The Lincoln Arc Welder as illustrated above is 
adapted for use everywhere, where electric cur- 
rent supply is available. 

An exception might be made of the railroad 
shop and street railway service for which special 
types of electric welder have been designed. 

This Welder consists of four simple units: 

1. — A Standard Lincoln Motor arranged to 
be driven by the regular shop current supply. 




Fig. 122. Lincoln Arc Wilder, Belt Driven foi usi 
where no electric power is available. 



54 



LINCOLN ARC VVKLDFRS 




Arc Welder direct - 
gasoline engine. 




2. — A Variable Voltage Generator delivering 
current of the proper kind for welding purposes. 

3. — A Control Panel mounting simple knife 
switches and connections together with a wheel 
switch for regulating current and a small am- 
meter and volt meter for measuring same. 

4. — The Lincoln Arc Stabilizer. 

This is practically an electro magnet which 
acts as a reservoir in which power accumulates 
exactly as it would in a reservoir on a water line. 
Whenever any extraordinary demand for power 
is made, the stabilizer supplies the extra power, 
without disturbance of the line. 

Two types of Lincoln Arc Welders, one for 
direct and the other for alternating current sup- 
ply mains, are shown in Figs. 120 and 121. 

Arc welding can be also used where electric- 
current supply is not available. In this case, 
the motor is not supplied and the generator is 
belted or direct connected to a gasoline engine, 
steam turbine or line shaft. This equipment 



can be supplied with a horizontal panel switch 
which makes it convenient for mounting on auto 
truck. (See Figs. 122 and 123.) 

This type of arc welding set is intended for 
use in places where neither mechanical nor elec- 
trical means are available for driving the welding 
generator. 

It consists of the generator of a standard Lin- 
coln Arc Welder direct coupled to a gasoline en- 
gine designed especially for driving electrical ma- 
chinery. 

It is equipped with control board and stabil- 
izer, the entire apparatus being mounted on a 
light but substantial lied plate which may be 
readily placed upon a flat railroad freight car, an 
automobile truck, a ship or wherever may be 
most convenient for the work in hand. 

Numerous uses for this type of arc welding 
machine readily suggest themselves, among them 
are shipyard and boiler work, the welding of 
pipe-lines in oil districts, steam railroad repairs, 
etc. 



55 



In 



.1 ■ . i ■ iin 



iiiiiiiii ■ ■ ii r 



LINCOLN ARC WELDERS 






i i i ' i i miimiinn 




I ' 



Lincoln Arc Welder for Railroad Shops 



This equipment is the same m all respects a^ 
the standard welding outfits described in page 
54. For convenience in railroad shop operation, 
however, it is mounted on especially designed 
trucks which permit it to be moved readily about 
the shop 

Special . idvantages of Lincoln 
Welders 

This outfit is intended to take care of one 

ator and can be placed at any point in the 

shop where the regular electric wiring is installed. 

The Lincoln Welder can be plugged in on any 
power socket anywhere where a five horse-power 
motor will operate, [n other words there need 
be no special provision for the welding outfit and 
no special wiring and re arrangement ol the 
shop. 

Other types of welder are designed to take 
care of several operators from one machine. The 
disadvantage of this system is that it requires 
a low tension distributing system carried from 
the welding machine to any station where weld- 
ing is to be done. Such a system requires large 



copper wire and i- a eery expensive installation 
tn make, and it does not offer any advantage 
w hatever. 

The Lincoln Arc Welder can always be taken 
to the place where the locomotive is standing 
and welding work can go on at the same time 
with other repairs. With other systems, the loco- 
motives all have to be brought to special stations 
for welding work or a low tension wiring system 
lias to be carried over the entire shop. 

Instead of moving the heavy locomotive about, 
the Lincoln Arc Welder, on its light truck can 
he taken anywhere even for a few minutes work. 
This is an important advantage of the Lincoln 
n i ie of equipment. 

With the Lincoln Arc Welder any number 
of operators desired can work on the same engine 
without interference, something which should not 
be overlooked. 

Should occasion arise to use carbon arc weld- 
ing, needing a welder of greater capacity, this 
can be provided by connecting two or three indi- 
vidual units as described on page 54. Occasion 
for this will practically never arise in the railroad 
shop. 



.. :i;.iiiii;iinii.i.:,i. 



WELDERS FOR STREET RAILROAD USE 




i Portable Lincoln 

\rc Welder for Streel Kai 
way use. 




Lincoln Arc Welder for Street Railroads 



This Welder has a motor designed to be oper 
ated by the power direct from the trolley line 
and this motor in turn drives the generator, de- 
livering the electric current at the proper voltage 
for welding. 

The type of welder formerly used for this 
work, consisted simply of a cast iron resistance. 
The current was taken directly from the trolley 
line, the resistance being used to reduce it to the 
proper voltage for welding purposes. This 
method was neither economical nor safe ami is 
rapidly being replaced by the Lincoln special 
equipment. 

Economy 

The Lincoln Arc Welder for street railway 
work takes only from 6 to 8 kilowatts from the 
trolley line and' gives 150 to 200 amperes weld- 
ing current. The resistance welder takes from 
80 to 100 kilowatts to do the same work. 

With the resistance welder the large amount 
of power taken from the line frequently results 
in burning of the trolley wire, in such a way that 
it either breaks or is weakened so that it breaks 
down in the first heavy storm. 



Safety 



With the resistance type of welder, the elec- 
trode in the operators hand carries the full volt- 
age of the trolley line. The slightest carelessness 



in handling may result in his getting the full 
current through his body, which would almost 
certainly result in death. Many serious accidents 
of this kind have occurred. 

Rail is Always Hot 

With the Lincoln Arc Welder, the rail is made 
the positive electrode of the system and the elec- 
trode which the operator holds is the negative. 
This insures that the rail will always be hot at 
the point where welding is done. The melted 
metal from the electrode will adhere to it readily. 
In the resistance type of welder, the rail is the 
negative electrode and there is frequently trouble 
in getting the metal to adhere properly. 

Shop Welding 

The Lincoln Arc Welder above is especially 
adapted for shop repairs on broken or worn parts, 
as it is exactly the same type of machine as is 
used for that purpose in other plants. 

Power For Grinder 

The motor on the Lincoln Welder is provided 
when desired, with an extended shaft to which 
a portable hand grinder can be connected by 
means of a flexible shaft. This provides motor 
drive for the grinder, when the operator is not 
welding:. 



57 







nun :i mi 



ELECTRIC ARC WELDING 






The following sections '>n Design of Welded 
Joints and "Ten Lessons in Electric Welding" 
are offered a< an aid in acquiring the knowledge 
and skill necessary to make successful applica- 
tions of the electric arc welding process. It would 
be impossible to write an) text book on this sub- 
ject which would include all of the things which 
n is necessary fi ir an i gineer t( i 

know in order to always make a successful ap 
plication of the process. The application of the 
process is a new science that has been explored 
in only a few of the directions in which it will 
eventually prove successful The arl of welding 
with an electric are is like any other mechanical 
art which may profitably be studied, but which 
only experience can perfect. 

The manual training idea has been foil 
out in the lessons on welding to a certain extent 
so that the operator may learn to weld by weld- 
ing according to definite instructions. The op- 
erator should follow the instructions to the best 
of his ability. It has been found by actual ex 
perience that if the operator merely "plays" with 
(he apparatus ami follows no definite plan dur- 
ing bis training period, little is accomplished so 
far as the learning of the fundamental princi 
pies involved is concerned. The operator must 
trv to make the samples required in the ievin- 



as g< " id as possible l'\ so doing, he will acquire 
a knowledge of the fundamental principles in- 
volved in any welding application. It is impor 
taut that tin- operator cut the welds as required 
in tbi' lessens and criticise his own workmanship 
and allow other competent workmen to criticise 
it for him. so that in the end he will know beyond 
question whether or not he is making t weld 
while he is i iperating the arc. 

It will be found much cheaper in the long run 
to have the operator spend enough time to be- 
come thoroughly familiar with the fundamental 
principles of welding during bis training period 
than to put him on commercial work and allow 
him to get his experience there. It should be 
thoroughly understood that the operator will not 
he an expert by any means when he has com 
pleted the samples required in these lessons. It 
requires a large amount of experience to become 
an expert operator and owing to the rapidity 
with which the process and apparatus are being 
developed, it is impossible for one man to know 
all there is to be known about electric arc weld- 
ing. The operator should continually study ways 
of improving his practice and if possible study 
the practice which has been developed by other 
experienced operators. 



Design of Welded Joints 



From an engineering point of view, even 
metallic joint whether it he riveted, bolted or 
welded, is designed to withstand a perfectly 
definite kind and amount of stress. \ n example 
of this is the longitudinal seam in the shell of 
a horizontal tire tube riveted boiler. This joint 
is designed for tension and steam tightness only 
and will not stand even a small amount of trans- 
verse bending stress without failure by leaking. 
If a joint performs the function for which it 
was designed and no more, its designer has ful- 
filled his responsibilities and it is a good joint 
economically. Regardless of how the joint is 
made the design of joint which costs the least 
to make and which at the same time performs 
the functions required of it. with a reasonable 
factor of safety, is the perfect joint. 



The limitations ,,f the several kinds of me- 
chanical and welded joints should be thoroughly 
undersl 1 

A bolted joint is expensive, is difficult to 
make steam or water pressure tight, but has the 
distinguishing advantage that it can be disas- 
sembled without destruction. Bolted joints 
which are as strong as the pieces bolted together 
are usually impracticable, owing to their bulk. 

Riveted joints are less expensive to make than 
bolted joints but cannot be disassembled without 
destruction to the rivets. A riveted joint, sub- 
ject to bending stress sufficient to produce ap- 
preciable deformation, will not remain steam or 
water pressure tight. Riveted joints can never 
lie made as strong as the original sections be- 



58 



I MINI 1 1- fill 



III .11 .11 III Ill III ■ 



ii in .iiiii' .' ' ■ ' .mm: mi. . 



DESIGN OF WELDED JOINTS 



I : MM -HI- .Mill II 



II MM .ii MII'IIM NINNl ■ Hill 



i 



cause of the metal punched out to form the rivet 
holes. 

There is no elasticity in either riveted, holted 
or autogenously welded joints which must re- 
main steam or water pressure tight. Excess 
material is required in the jointed sections of 
bolted or riveted joints, owing to the weakness 
of the joints. 

Autogenously welded joints have as a limit of 
tensile strength the tensile strength of cast metal 
of a composition identical to that of the joined 
pieces. The limit of the allowable bending stress 
is also set by the properties of cast metal of the 
same composition as that of the joined pieces. 
The reason for this limitation is that on the 
margin of an autogenous weld adjacent to the 
pieces joined, the metal of the pieces was heated 
and cooled without change of composition. 
Whatever properties the original metal had, due 
to heat or mechanical treatment, are removed by 
this action, which invariably occurs in an auto- 
genous welding process. Regardless of what 
physical properties of the metal used to form the 
joint may be, the strength or ability to resist 
bending of the joint, as a whole, cannot exceed 
the corresponding properties of this metal in the 
margin of the weld. Thus assuming that an 
autogenous weld be made in boiler plate, having 
a tensile strength of 62,000 lbs. Assume that 
nickel steel, having a tensile strength of 85,000 
lbs. be used to build up the joint. No advantage 
was gained by the excess 23,000 lbs. tensile 
strength of the nickel steel of the joint since the 
joint will fail at a point close to 62,000 lbs. If 
appreciable bending stress be applied to the joint 
it will fail in the margin referred to above. 

The elastic limit of the built-in metal is the 
same as its ultimate strength for all practical pur- 
poses but the ultimate strength is above the elas- 
tic limit of the joined sections in commercial 

structures. 

In spite (if the limitations of the autogenously 
welded joint referred to above it is possible and 
practicable to build up a joint in commercial steel 
which will successfully resist any stress which 



will be encountered in commercial work. 1 he 
advantage lies in the built up structure and the 
inherent steam and water pressure tightness oi 
a welded joint. 

The fundamental factor in the strength of a 
welded joint is the strength of the material 
added by the welding process. This factor de- 
pends upon the nature of the stress applied. The 
metal added by the welding process, when sub- 
ject to tension, can be relied on in commercial 
practice to give a tensile strength of 45,000 lbs. 
per square inch. This is an average condition; 
assuming that the metal added was mild steel 
and that the operation was properly done, the 
metal will have approximately the same strength 
in compression as in tension. When a torsional 
stress is applied to a welded joint the resultant 
stress is produced by a combination of bending, 
tension and compression, as well as shear. The 
resistance of the metal to shear may be figured 
at 8/10 its resistance to tensile stress. The 
metal added by the welding process, with the 
present development in the art of welding, 
will stand very little bending stress. An auto- 
genously welded joint made by the electric arc 
process must be made stiffer than the adjacent 
sections in order that the 1 lending stress shall 
not come in the joint. An electric weld, when 
properly made, will Lie steam and water pressure 
tight so lens as bending of members of the 
structure dues not produce failure of the welded 
joint. 

Little is known at the present time in regard 
to the resistance of an electrically welded joint 
to dynamic stress, but there is reason to believe 
that the resistance to this kind of stress is low. 
However, owing to the fact that in most struc- 
tures there is an opportunity for the members 
of the structure to flex and reduce the strain 
upon the weld, this inherent weakness of the 
welded joint docs nut interfere seriously with 
its usefulness. 

A few tests have been made of high frequency 
alternating stresses and it has been found that 
using the ordinary wire electrode the welded 
joint fails at a comparatively small number of 



59 



iiiiini: i! nil ..n. 




Ill i!l ■ ! 



' .1 Hill ' .1- 



ELECTRIC ARC WELDING 



























Fig. 132 



ii 



alternations. This is of little importance in most 
structures since high frequency alternating stress 
is not often encountered. 

Stresses in Joints 

The drawings reproduced on pages 60, 61, 62 
show several typical metallic joints and the 
stresses which are brought to bear on them. The 
method of welding is indicated. 

In Figure 126 it will be noted that a re-enforc- 
ing plate is welded to the joint to make the joint 
sufficiently stiff to threw the bending outside the 

weld. 

Figure 127 shows a joint in straight tension. 
Since ii" transverse stress occurs the heavy re- 
enforcing of Figure 126 is not required. Just 
enough re-enforcing is given the joint to make 
up for the deficient in tensile strength, of the 
metal of the weld. 

Figure 128 show another method of building 
up a joint that is in straight tension. It should 
be noted that in both Figure 127 and Figure 128 
as much re-enforcing is placed on one side ol a 
center line thru the plates as is placed on the 
i ither. 

129 shows the original form of lap joint 
such as is used in riveting. The method shown 
for welding this joint is the only method which 
can be used. It cannot be recommended because 
such a joint, when in straight tension, tends to 
bring the center line of the plate into coincidence 
with the center line of the stress. In so doing an 
vsive stress is placed on the welded material. 

Figure 130 shows the construction iwd in cer- 
tain tanks where a flanged head is backed into 
a cylindrical shell. The principal stress to 

•<■,] by the welded joint is that tending to 
push the head out of the shell. The .velding 
process indicated in the figure will successfully 
do this. Owing to the friction between the weld 
and the shell, the outer weld would be sufficient 
to hold the weld in place for ordinary pressure. 



60 



■ : ■ INI" ■ IIMM ■' IIHIIM 



lllllillllimillllimlliiiliiiEiillllinliiliiiillll 



llllllllllllllllllllllllllllllllll 



DESIGN OF WELDED JOINTS 



III Illlllllllllllllillll run: llllllllllllllllllllllllll 



I'll Mill' Illl 





Fig. 133 




For higher pressures the inside weld should be 
made in addition. 

Figures 131 and 132 show another method of 
welding a flanged head to the cylindrical shell. 
These methods are preferable t<> the method in- 
dicated in Figure 130. Figure 132 represents the 
reci immended practice. 

Figure 133 shows a plate and angle structure 
which might he used in ship construction. The 

particular feature to notice in the welding prac- 
tice indicated, is that the vertical plates do not 
reach, the entire distance between the horizontal 
plates. This is merely a method of eliminating 
difficulties in welding the plates to the angle. 

Figures 134A, 1341'.. 134C and 1341* show a 
method of welding a crack in a locomotive 
frame. Hie object in this practice is to reduce 
the amount of metal deposited by the electric 
welding process. The metal of the plate lami- 
nated structure is of better quality than the weld- 
ing process will deposit. And also a large 
amount of time is saved by this practice. 
The plates should lie \s or > _. inch in thickness. 
/;; making any weld, the smallest amount of 
metal should he added by the welding process 
which is possible to add with perfect fin 



Fig. 134A 




Fig. 1341? 




I.UD 



i 1 niiimiiiiiiiiiiiiiinmimim ■ nun n 




r. hi i mi n .in 



mi in i ii ■ n mi ■ 'v i [i.iiimilliiiii 



ELECTRIC ARC WELDING 



c 



o 



o 



- 






i II iiiiiiiii I nil ' iiiili : ;: i mi mi: mi 




Figure 135 shows a method of welding a head 
into a cylindrical pipe. The thickness of the 
head should lie approximately twice the thick- 
ness of the wall of the pipe. The extra thickness 
plate is to gain sufficient stiffness in the head 
to make the stress on the welded material purely 
shear. The pressure from the inside tends to 
make the head assume a hemispherical shape. 
This would place a bending stress on die welded 
material if the head were thin enough to give at 
the proper pressure 

Figure 136 shows a method of welding a crack- 
in a tire In >x sheet. The thin plate backing in- 
troduced at the weld makes the operation very 
much easier for the operator and produces the 
re-enforcing of the water side of the tire box 
sheet w hich is most desirable. 



Data for Calculations 

i cu. inch of steel weighs .28 pounds. 

3.57 cu. inch of steel weighs i pound. 

One pound of 5 32 inch electrode may he de- 
posited in 27 minutes with 130 amp., 16 volts. 

25 to 30'' of all electrode is wasted in "ends." 

15 ft. of 5 32 inch electrode weigh one pound. 

One K. \Y. II. of electric power will produce 
3413 B. T. U. of heat. 

On straight-awav welding the ordinary operator 
with helper will actually weld 75'' of the time. 



'.j 



WELDER PARTS 



nun mm: i i 'mm I i i i mil' I ' II iMIIIh miiliil mm mm nihil i m M miiiiiniiiiiiil 1,1 




No. 
1. 



8. 

9. 
in 
1 1. 
12. 
13. 
14. 



Xo. 

I 



IN. 
10. 
20. 




Dust Cap. Inner 
I lust Cap, i lutei 

End 
S.K.F. Bearing 
Insulating Washer 
Tube, Brush 1 [older 
Commutator Bar, M 

End 
Bra. k. 1 

Brush Holder, Motor End 
Shaft 

Commutator ' ap 
Shrink Collar 
Armature Coils 
Eye Bolt 
Statpr Lamination 



Xo. 



Frame Rivet Tubes 

Pole Coils, Motor End 

Blower 

Field Coils, General. u End 



DIRECT CURRENT SUPPLY 

N. 
19 



Armature Lamination 
Frame Bolt 
End Plate 
Mica Ring 



29. 

31.' 
3 2. 
33. 
34. 



Commutator Bar, 

Welder End 
Brush Holder, Welder 

End 
Clamping Washer 
Rocker 
Felt 

Lock Nut Spring 
Dust Cap, Generator End 
Lock Nut 

Spring. Brush Holder 
Finger Stud 
Finger 
Brush 

Blower Support 




Brush 

I ing< : 

Shaft 

Commutati i! Cap 

Mica Ring 

Felt 

S K F Bearing 

Lock Xut 

I lust Cap, I lut. '. 

Lock Xut Spring 

I >ust ( ap, Inn. r 

i lamping Washer 

Insulating Wash, i 

Rocker 

Finish Holdei 

Commutator 

Rracket, Weld. 

End Tlate. We 

Ai mature Ci 

Field Coils 



FIG. 



End 



End 



No. 
21. 



23. 
24. 



.In. 
31. 



138. ALTERNATING CURRENT SUPPLY 

No 
33. 
End 34. 

S5. 



Shrink Collai 
Frame Bolt, \\ - Id 
I y, Bolt 
Frame Rivet 

Welder End 
Blower 

End Plate, M. 
Si. nor Coils 
I- 1. mi, Bolt, 
Frame Rit . I 

End 
Rotor Rods 
Rotor End Ri 
King 



Tub. 



Mot. 
Tube 



End 



I' 
Mnl 



16 

38. 
S9 

40 
41. 
42 
4.!. 

44. 



Shrink Collar, Motor End 
Bracket. Motor End 

ting Ring, Excite] 
Grease Cup 
Exciter Frame 
Poles 

Field Coils 
Armature Ci iils I 
Mi, a Ring Exciter 
Commutator E ■ ■ itei 
Brush Holder Exciter 
Insulating Washei - 

Exciter 
Tube, Brush Holdei 



56 

57. 



el. 
1.4, 



Clamping Washer 
Bracket Exciter End 
Rocker Exciter End 
Dust Cap 
S.K.F. Be.iiiug Exciter 

End 
Dust in' Ex. iter End 
Insula! ion 
Exc iter Shaft 
Terminal Block I ■■ ■ it. I 

End. 
Pig I ol Clip 
1 lust . .us Motni End 
Connecting I ' i i i 
l.,.ck Washer. Motor End 
S K F Bearing 
lin^t Cap, Inner, Motor 

End 
Felt 

Spring. Brush Holder 
Connectoi - 
Stud, Finger 
Connecting Ring 
Blower Suppon 




TEX LESSONS IN ARC WELDING 



. inn mum niiiiimimimiiiiiiit : mm ■■ iiiiiimiiiiimmiimmmiiiimimm n miimmimm in iiiimii 



' ii ■ ii 



c 




200 






! 



','. , 1,1. 



(A) I- lectrodi II i i I ■ ? mil I'it-ld 



1 
1*1 

K , Kin 



(S) Stal 

l \\ 1 \\ I 



LESSON I 



'The .Ire Welding Machine 

It is 

with the 

the arc fi >i « 

reproduced showing the names of parts oi the welder 

set. It is not nei 

the names of the detail parts except that he should 

understand tin !• » atii m and f the es 

parts as folli i\vs : I >nish, Brushln ilder, i 

Exciter Commutator. Field Coils, Motor, I- 
( Ireas e i 'up, Ball 1 leai ing s, Shal < . ! '■ 
Poll I See [, , . \ny elect riciai 

thesi part; is inl- 

aid, to do so. 

The arc welding electrical!;, separati 

from the motm which drives n \ welding generatoi 
maj be driven b_\ eithei 

altei n >r or hy a I - asoline 

engine. Tin source of power to drivi tin welding 
generator liing whatever to do with tin 

havior of the weldi provided 

it is furnished in sufficient quantity and turns the ■ 
ing generatoi al the propel speed. Hie motor end of 
the welding machine is like am other motor of the same 
rating. 

Tlu- principle of operation of the welding generator 
i~ very simple to the man who has had some experi- 



,,\ it ii direct current generators but is difficult 
else to understand For the benefit oi 
man who has had electrical experience, ii is sufficient 
, that the welding generator is merely a spe< II 
ateh excited generator with a differen- 
tia] compound winding and that an inductivt ballast is 
used in the arc circuit Ii is desirable for the operator 
to understand the principle ol operation of the welding 
-, t as well as tin electrician understands it but it is not 
itely necessan The accompanying cut shows the 
ill ampere characteristic and the wiring diagram ol 
, elding g< nei at >r. 

Iding outfit should alwaj s be install* d 
electrician. All cables are labeled and the direction of 

rked so that m i difficult} w ill : " ■ 
enced in installing the outfit without the use of a wir- 
ing diagram. 

The Stabilize! is made up of coils of wire 
a laminated steel core and it- purpose is to make the 
.ml r.iM t, , ,pei 

\u electrician should explain to the operator the 
method .if starting the < mtfil 

The control panel contains the apparatus with which 
the operator controls the behavior of the welding gen- 
erator, adjusting it to give the proper amount of heat 
for welding. Two cuts are shown showing two types 



64 






Illllll 



TEN LESSONS IN ARC WELDING 



.' !:. 



ill, I Hull ii ' llll ' 




• •I control panel used. The portable type accomplishes 
the same thing as the stationary type. The voltmeter 
and ammeter are left off the portable type on account 
"f the fact that they arc too fragile to stand the rough 
use to which lhej would lie subjected on portable 
equipment. 

Fig. 142 shows the ordinary equipment used by tin 
operator, and welding table. Referring to Fig. 154. the 
proper clothing for an operator is shown, — it consists 
of black cap. unionalls, cotton gauntlet gloves, split 
leather apron. 

Adjustment of Machine 

1. I (pen main switch and control switch on panel. 

2. Start welding set. 

3. Turn rheostat as far as it will go to the left. 

4. Close control switch into position marked 100. 
(In this position the current in the arc will be approxi- 
mately 100 amperes, i 

5. Put a piece of .-:/' welding wire in the metal elec- 
tn ide holder. 

i). Place a piece of boiler plate scrap or. welding 
table ti i practice on. 

7. Close main switch on panel. 

8. Sit down on stool in front of welding table. 
Take band shield in left hand, metal electrode holder 
in right hand. With shield held in front of face touch 
boiler plate with end of welding wire. The result will 
be a spark and the welding wire will stick to the boiler 
plate. Let go of electrode holder and open main switch 
Oil panel. 

9 With a new piece of welding wire and face shield 
in front of face, scratch welding wire sidewisi on 
boiler plate to get spark, then draw welding wire about 
an eighth of an inch away from the plate. Hold weld 
ing wire vertical to boiler plate, otherwise arc will 
be difficult to start. 

Repeat the above operatii n until an arc can be main- 
tained as long as desirable. The beginner should burn 
from 75 to IOC pieces of welding wire at this practice, 
observing through the shield what happens in the arc. 
\s the operator becomes mure skillful he should try 
to held a shorter arc. The proper length is about an 
eighth of an inch. The operator should spend about 
15 hours on this kind of practice. The amount of 
current or ampere- required for welding depends prin- 
cipally upon the sixe welding wire used. Three-six- 
teenths inch welding wire requires about 150 amperes. 
(Turn rheostat as far to left as it will go and close 
control switch into 150 ampere position.) For points in 
between ltxi and 150 amperes turn rheostat to right with 
control switch in 150 ampere position. 



Aninii'tc 




t'ig I tO, Statiunan Panel 





Fist. 142. Operator's To 



65 



L 



TEN LESSONS IN ARC WELDING 



ii inn inn in nun in :■ .;i 



■ II! ■ 



iiiiiiiiiiiiii il Ulim limiiil mil in Miimi ii 



LESSON II 

Starting the Arc 



This exercise deals with the proper method of 
starting and stopping an electric arc. The beginner 
usually draw- an arc and starts to weld at whatever 
poinl the arc happens to starl operating properly. In 
other words, the beginner usually wilds where it is 
possible for him i" weld rather than welding in a pre- 
determined place The purpose of tin- exercise is to 
give the operator sufficient control of the arc t" en 
able him to weld at any place be may decide 

1. Place a piece of scrap hoiler plate on the welding 
table. With a piece of soap stone marls a line 

the plate. Now weld a bead as nearly as possibl. 
to the right of this line. Make the bead as stl 
as possible. Repeal this operation until a perl 

gilt l'e. id * " from the pri an be 

laid down. 

2. In tlii- exercise the nperatoi should print bis 
initials on a piece id scrap boiler plate and weld a 
bead i >\ er the lines I [a\ ing pi 

initials in this manner lake annthei piece ol 
boiler plate and make the initials the san iz< with 
out previously printing them with soap ston<\ This 
ild be t . peated until tin i can 

reproduce bis initials without following the lines. The 
purpose of tins cxi -or to 

control an air and had it in a predetermined dip 
It also invob i 5 [be ii aining of th 
see where be is leading the arc. I In- will be di 

at firs! owing to tli,- fact that the operator ran see 
nothing but the are itself tin ^lass 

i ator should n and chisel 

and i ■ of several beads w hii 

It will lie found that the beginning of the 

I- usually not -| ],;, 

is dn.' to the t'.i, i thai I 

-: .it. : |"hi . ipei ition of 

weld 

is m.i. the head. 

A- The end of the head is quite a- important 
beginning. In referring to beads which the beginner 
ha- previously made it will he found tl sider- 

ahle crater has been left al the point at which th. 
was broken. The objection to this crater is that it is 
-tat! welding at this point when it is de- 
le t.i Continue the head er may be filled 
: i the are i- finally bi i >ki n by mi wding 
down the are until the desired amount of metal is 



added, and breaking the are suddenly by pulling the 
harply to one side. The operator should practice 
this operation until be is able to finish a bead leaving 
a crater of not to exceed Pc of an inch in diameter. 

5. Thi .loo,, outlined in the preceding four 

aphs should occupy at least tin hours of tin- 
nine The following sample is to be made 
a- to the record of the operator's ability to start and 
sti ip an arc pn iperly : 

Material re. pined: one 12"xl2"xj4" piece of boiler 
plate; three si es ol electrode are required /<;". ■■'2", 

\o marking ip stone is to he done 011 the 

plate. Referring to the photograph reproduced here 
with, the first three rows of heads are to be made 
wire using approximately 150 amperes. Each 
head should be one inch long. ITie beads should be 
quarters of an inch apart. They should be 
straight and parallel, Each head should have a per- 
i.ii weld at it- start and a very small crater at the 
finish. The next five head- are to he made using 

-nd the next two. electrode with 

about 125 and 100 amperi pectively. < hie side ol 

lit. should he completely welded in accordance 

the above instructions. The plate should then 

he turned over and 1 leraticn repeated am! pei 

on the oilier side of 'he plate. 




Fig. 143 






mm run: mi m : \ inn 



nun i if i in' 



n .1 .:.. mm m mill 1 nllih mil i mil 



TEN LESSONS IN ARC WELDINCI 






iiiinmiiiiimiimiiiiimiiii 



Illlllll ■ ■ I! 1 




LESSON III 
Building Up Operation 



The purpose of this exercise is to show the operator 
the proper method of building up several layers of 
welded material. It is assumed that in Lesson II the 
operator has learned to deposit metal from the welding 
wire on a piece of boiler plate and have it entirely 
welded along the line of fusion. Until the operations 
outlined in Lesson II are completely mastered, it is 
useless to proceed with the exercise of building-up 
operations. 

Material required: One 10".\12"\ ' .." piece of boiler 
plate. One size of electrode, h of an inch, is re- 
quired. The current should be about 125 amperes. 

Referring to the photograph reproduced herewith. 
three pads are to he built up on the face of the plate. 
These pads are to be 6" long. 2" wide. 1" high. The 
first pad starting from the left hand side of the plate 
is to be built up without any particular design or pat- 
tern, and without brushing or cleaning of the oxide- 
covered surfaces. 

The next pad is to be built up following the definite 
pattern. First, brush the spot on which the second pad 
is to be built very thoroughly with a wire brush. 
Second, build up a single layer of metal the width of 
the pad using a series of beads laid along the 6" 
dimension, always starting at one end and finishing at 
the other end. Having deposited the first laser, the 
oxide covered surfaces must be brushed thoroughly 
with a wire brush. Each layer should be brushed at 
least three minutes. The second layer of the pad should 
be built up so that the beads run at right angles to the 
beads of the first layer, i. c, the heads are parallel 
to the 2" dimension of the pad. This practice is com- 
monly called "lacing." The second layer to be as 
thoroughly brushed as is required upon finishing the 
first layer. Each succeeding layer should be thoroughly 
brushed. 

The third pad is to be built up in exactly the same 
manner as the second pad with the exception that in 
place of brushing the work with the wire brush onlj 
between each layer, the oxide must be entirely cleaned 
off by the use of the hammer and chisel. It will be 
noted that the oxide may be removed bj comparatively 
light blows on the chisel. It is not necessary to cut 



away am metal to knock the oxide from the top of 
the layer with a chisel. The wire brush may be used 
to brush the oxide off the metal after it has been cut 
away with a chisel. 

The operator has now completed three pads. The 
first pad illustrates how- welding should not be done. 
The second pad illustrates a fairly satisfactory practice. 
The third pad illustrates the best practice. If possible 
the operator should have this sample sawed diagonally 
through the three pads. It should then be set up on a 
grinding machine and a fine surface ground on the 
cut section of the pads. This can be done in a tool 
room The ground surface should then he painted 
with diluted sulphuric acid or tincture of iodine. It 
will then be easy to compare the quality of the metal 
in the three pads. The operator should also observe 
carefully the line of fusion between the pads and the 
original plate. This fusion must be perfect if the weld 
is of any value. The photograph reproduced herewith 
illustrates the appearance of a good line of fusion. 




Fig. U4 









Fig n 



67 




iii. i<- ii i i i.iiiiiiiiiiimiiiiitiinmi. 



TEN LESSONS IN ARC WELDING 



LESSON IV 

Plate Welding 



lln- exercise is one oi the rtmsl important of the 
scries Inf. him- the welding of plate is tin most frequent 
application "t the electric arc welding process Phe 
welds which must he made in le ot 

plate, sue h .1 - tanks, ire in it alw a\ 
the operator must K irn to weld not onh in the hori 
. iin.il posh ion bul ei tical and 

positions. Three samples are to be made as the n 
of the operator's abilih to weld in the horizontal posi 
nd the vertical and straight o > 

il required Six II 
plate hex eled 45 di i me 12" 

125 t" 150 amp 

i sin mid spend appi - iximati I 
In mi- in ptili mi i i.i t \ prai i ice. Si \ eral neci 
boiler plate should be beveled and 
sin >\\ n in the .ii ' i impam it 

lid then be set up vei ticallj and w i ldi 

ttom and weldit hould 

i, own r in arrivin best 

■ . make li w eld in this position, 
different methods and observing the following p hits 
Does the weld extend completelj from the inm 
the < uii-i edges o| tin plate Doi i i oi the 

■i e> pan 'ii I 1 

affect tin characti i ot the weld ? Does the exp n 
and 1 1 inti ai tion i aused by I 
produce wai ping oi bin kling \ i tet H 
satisfied himself on these points two pi crap 

boiler plate should be bevi Ii .1 and pi. i i dtion 

,,,],■ . peratoi 

,i trj to weld them together in this position. 
« elding from the un I lie i 'pei at 

.in iii. pieces approximated} one sixteenth ot an 
fi it this exi .i !-•' I of weldii 

nsiderable amount of practio 
to masti i It will be found that the operation « ill I" 
some" Ii: t i' i-H r ii 150 amperes i 

trodi rsl In welding be' i Ii -1 ratot 

should remember that the welding wire >r eleel 
should be held as nearh perpendiculai 
welded as possible, and that 
nly he <n - ointlisht a lined. 

I)i, operator should pa\ particular attention to the 
dift'i : : mul between a long arc and a sin >rt one 

.\ I,,,,- an a distinct hissing sound. 

It is impo I weld with such an arc A 

arc has a rapid lire metallii click which ma\ 

guished. The operat' i sh mid maintain a 
1 classes of welding. Where possible an 
trii i.in should be asked to connect a low reading volt 
meter across the arc so thai tin eoltagi ma In read 
while the operator is welding. The coll metei should 
read from 15 to 18 volts while the are is in open 
The greatest amount of beat is obtained on the work 
whin the electrode holde is negative. This is the 
proper connection for both metal and carbon electrode 
work. 



While the arc is in operation there will be a circular 
pot oi molten metal upon the work. The operator 
should concentrate bis attention upon the sun- of this 
molten spot i i metal which is in the direction of 
motion of the electrode This may also be described 
a- the forward edge of the circular spot. Tin 
should be directed on this point, since it is at this 
poinl that tin greatest amount of heat is desirable. // 
in/ elei trii weld only win 

/ from the welding iWn is 




Tacked 





l-'iy. 147. Horizontal, Vertical and Overhead S 



68 



"'in"!- i ; ' ii i i 11 linn minim mi 



inn ■ ' ...i. 



iiWHi : ■ - "' . m mil 



TEN LESSONS IN ARC WELDING 



iilllllilllllllllllllllililiill Miiiimiiimiilmiitiitiiiiiii 



mil iiihiiiiiiihiiiiiuii iiiiiiin [nun 




throicn into molten metal on the piece being welded. 
If the globule of metal drops on metal which is not 
molten it may stick but it will not be welded. The 
operator should study the action of the metal in the 
heat of the arc very carefully. The operator should 
begin to realize at this point that merely holding an 
arc is not necessarily welding but that the art of weld- 
ing is ninety per cent brain work and ten per cent 
manual labor. 

2. Place the horizontal sample of welding in posi- 
tion on the welding table. Put a ,<Y' electrode under 
each plate in a position parallel to the beveled edges 
and ibout _■" from the lower edge of the bevel. This 
will raise the beveled edges higher than the square 
and give the -ample a ridge through the center. 
The object of this practice is to allow for the warping 
of the plates by the heating of the arc. After the 
sample is welded it should be straight with the two 
plates squarelj in line. Place the edges l s of an inch 
apart all the w,<\ across. Tack the pieces together as 
shown in Fig. 146. Now with 14(1 amperes and a 3V 
electro. le. weld one layer in the bottom of the bevel 
in about 3" sections. B\ this is meant that the operator 
should weld three inches, skip three inches, weld three 
inches, skip, etc., until he has gone all of the way across 
the plate, then go across the plate again, filling the 
three-inch gaps. This is to minimize the effect of the 
heating. The plate will then be welded with one layer 
all the way across. The operator must manipulate the 
arc in such a manner as to weld the lower edges of the 
plate completely together, 1. c., the metal from the 
electrode must run clear through the plates and be 
firtnh welded >n the edges. The operator should then 
take hammer and chisel and clean the oxide from the 
surface of the welded metal very thoroughly. The 
second layer may now he welded into the bevel start- 
ing at one end and finishing at the other end. This 
layer should lie thin and should not extend higher 
than the upper surface of the plates. Chip oxide from 
surface of welded material and put the third and fin- 
ishing layer on the weld. The third layer should ex- 
tend about o. of an inch beyond the edge of the bevel 
on each plate, and ' s " above the upper plate surfaces 
The plate should now he turned over and a re-enforce 
ment of equal width anil thickness put on the other 
side. The purpose of this practice is to make the sec- 
tion of the weld equal on both sides of a center line 
through the metal of the plate. If the weld were re- 
enforced on one side and not on the other the stress 
would be concentrated on the side which was not re-en- 
forced when the weld is put in tension 

3. The two plates should be tacked together as in 
first exercise but in this case the beveled edges are to 
be set vertical, as shown in Fig. 148. The weld is 
to he made according to a definite pattern start- 
ing at the bottom and finishing at the top. This 
pattern is triangular. The operator should start on 
the right hand plate at a point of about ;';■. of an 
inch to tht right of the beveled edge, holding the 
welding wire as nearly perpendicular as possihle to the 
surface being welded. The movement should be along 
the beveled edge of the right hand plate toward the 
farther edge, then along the beveled edge of the left 
hand plate toward the nearer edge, extending to a 
point 1% of an inch to the left of the bevel on the left 
hand plate, then across to the starting point. Five- 
thirty-second electrode with about 125 amperes is to 
he used. The operator must pay particular attention 
to see that the farther edges of the plates are securely 




welded together \ considerable amount of metal 
should he run through the edges to make this certain. 
4. For the sample of overhead welding, the plates 
may he tacked together as shown previousl} except 
that the opening should be approximately ', of an 
inch. The two plates are to he welded in the overhead 
position after they have been tacked. Several pieces oi 
plate ' s of an inch thick, l'j" wide and 6" long are 
to be cut, and a ■.'_■" electrode should he stuck on ex- 
treme edge of one of the corners so that the electrode 
stands out perpendicular to the piece. The purpose oi 
the electrode is to serve as a handle. This A" piece 
is to he pushed through quarter inch opening between 
the plates front the under side and to he brought 
into position so that it wall form a backing for 
'.he weld. Fig. 147 shows the position of this 
plate. After the plate has been placed in position 
it may be tacked. The Use of this plate makes the 
overhead welding somewhat easier than welding with- 
out its use. Si. hi the overhead weld at the center of 
the job and weld toward one end. A definite pattern 
should he followed. Start at the lower edge of the 
right hand plate at a point ,;. of an inch to the right 
of the bevel. Continue along the beveled edge of the 
right hand plate up to the backing plate, across the 
backing plate and down the beveled edge of the left 
hand plate to a point ; of an inch to the left of the 
bevel. This will form the first head. Xou start the 
second bead at the beveled edge of the right hand 
plate and on top of the first head, and till in. as far 
as possihle, the opening formed by the beveled edges of 
the plates. A third head will he required to complete 
this operation. The operator now litis two surfaces 
to weld on, the surface formed by the welding ma- 
terial, which should he approximately vertical, .and the 
surfaces of the plates to he welded". Idle pattern of 
the first pad should he followed out from this point 
on welding at the junction of the previous!} welded 
material, and the surface- of the plates being welded 
together so far as tins is possihle. This make; thi 
weld more a vertical weld than an overhead weld and 
considerabl} simplifies the operation. The operator 
should use about 150 amperes to start with, cutting 
it down to 125 or less a s the [date warms up. Having 
completed one end of the weld in this manner the other 
end may be welded in exactly the same way. It will 
be found that the backing plate will warp and tend to 
get out of contact with tin- beveled plates. This will 
not interfere with the welding and will enable the 
operator to re-enforce the weld 011 the top side, which 
is verv desirable. 



69 




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mum miiutii i: ii 



TEX LESSONS IN ARC WELDING 



LESSOX r 
Thin Plate Welding 



This exercise is to give the operator some experience 
on thin plate welding. The difficulties encountered in 
thin plate welding are comparatively simple of solution, 
and the operator is lett to use his own resources I" a 
considerable extent in making the sample. The great 
difficulty in welding thin plate arises from tin tendencj 
of the arc to burn through the thin plate owing to the 
great intensity of heat. Practically all thin plate is 
covered with a heavy scale of blue oxide, and it is 
necessary to get this oxide cleaned off in order to 
make a good weld. This may be done with hammer 
and chisel or a sand blast The operator has already 
found that it is neces ave clean metal in 

to make a good weld. The quickest and best wa> of 
getting clean metal is to sandblast the surfaces to be 
welded. This applies to metal of all thicknesses. The 
reason blue oxide gives tin operator trouble is that it 

is a verj | i conductor of electricity, and it is hard 

to get the arc started on an oxide-covered surface and 
also that the oxide gets into the metal of the weld 

Material required: One piece of 24"x30" sheet steel 
approximately fa ot an inch in thickness i .node 

with ''II to HKt amperes. 

1. The operator should study the drawing i 
duced i ippi >site i f ig. 151 i and lay out the pieces to be cut 



mi order to make the sand blast pot shown. This will 
leave some scrap material around the edges which 
should lie cut with a hack saw into pieces approximated 
_'"x4". The operator should practice welding these 
scrap pieces In laying them down on the welding table 
and welding a straight seam. One sample should also 
lie welded with the two pieces perpendicular to each 
other as shown in accompanying cut. (Fig. 149.) Ap- 
proximately two hours should be spent on this practice. 

_'. The op( i ati ii should iv » 
cut the plates necessary to form 
the -and blast pot and weld them 
together. It is suggested that the 
heads be made smaller than the 
shell so that the) fit on the inside. 
They should set hack from tin 
of the shell about ' ,". ( hie 

small hole should be burned 

i at the location of one of 
the fittings in order to allow tin 
heated air to escape while the 
welding is being done. The fitting 
can he put on the sand Mast pi it at 
some later tune b) the operator [,-;„ 14 ,, 




LESSOX II 

Pressure Jl'cld'inn 



This exercise is in the nature of a test of the ability 
of the operator to make a solid homogeneous weld 
which is properlj and thoroughl) done. A great null) 
electric welds are subjected to steam or watei pressure 
and unless they arc properly ni.uk the) will show leaks. 
and will fail at a point below the pressure for which 
they were designed It is very important that the op 
eratoi should know when he is making weld. 
If he does not know this Ins work is entirely worth- 
less, He is as i r a workman as the jeweler who 

must smash an expensive watch in order to find out 
how it was made \ skillful operator, who has a 
reasonable degree of judgment and intelligence, knows 
when he is making a good weld. If he has made a 
section of a weld which is not good, he should eithei 
cut that section out and reweld it or inform the man 
responsible fur the job of the fact that a particular 
section is faulty. A man who will lie to himself in 
regard to the quality of his work, will he to the man 
wdto is responsible for its quality, and is worse than 
worthless as a skilled operatoi 

Material required: (hie 18" section of 8" wrought 
iron pipe or seamless steel tubing, two 
plate heads to fit mi tin inside of the pipe or tube. 
These heads should be beveled 45 degrees on the cir- 
cumference, o puces ,,i 1" black wrought iron pipe 6" 
long, one puce of m" or 1" pipe according to the size 
watei pipe used in the shop where the welding is done. 
This pipe is to be connected to the water system so 
that the completed sample may be tested under pres- 
sure. Six holes are to be drilled at intervals of 2" 
into the 8" pipe to take the six 1" pipes. One hole is 
to be cut to take the V or 1" pipe. 

1. The heads are to he welded into tl i 
shown in the accompanying cut. (Fig. 150.) The op- 
erator must be careful to hold a short arc and so far as 
possible keep the electrode perpendicular to the surface 
being welded. The surfaces which are to be welded must 



an and tin oxide must he removed from each 
layer of metal before the next layer is welded, h> the 

use of sand blast or hammer and chisel. The 1" pipes 
are spaced close enough together so that .some diffi- 
culty will he experienced in making a good weld be- 
tween pipes. This is done purposel) because it is a 
difficulty frequently encountered in pi. nine The up 
erator should mark with chalk the spots where he 
believes, owing r • ■ the manner in which he welded the 
sample, that the leaks will occur Weld the ends of 
the -ix 1" pipes shut. 

2. The operator should connect the sample to the 
Haln system of the shop and test it fur leakage i It is 
advisable to pour the sample full of water before the 
connection is made so that it will be entirely tilled with 
water when under pressure. I If leak- are found the 
operator should cut out that part of the weld, examini 
the weld and find if possible the cause ,i the leak. 
The defective spots should be rew elded and the test 
ited. 




7" 



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TEN LESSONS IN ARC WELDING 



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- d Blast Pot Made by Arc Welding. 



71 



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TEN LESSONS IN ARC WELDING 



LESSON III 

Miscellaneous Jobs 



mi mini "I 1 I nun 



The object of this exercise is i - give the opcratoi 
in idi Few "I tin manj different kinds of ap- 

plications of thi proce \ gn it deal depends upon 

ieral t's natural n Iness in planning a 

job One of the difficulties is in knowing how l 
about i that it maj be di 'tie u ith tin 

ire highl\ skilled tl 
is. the easier will be tin waj which he chooses to pel 
form the operation, This involves careful planning ol 

irted. Tl ■ ■• who 

(Mini- a he is going I 

the job will have little success in doing it. V has 

in welding depends 
the usi rain than upon the use 

I In- - - .In mid In- able to l 

- ,i i ei tain job and explain tin 
■ - dn ilu- job in that particul; 

Mati i ial i * quii '-'1 ' me i i\ eti d 
Fig. I ' 153 

not conform I 

ihould take 
ilei plate, and tacl 
-ilu of a lap joint. I In liould 

then I" -it up in the vertii 
xvi Idi underside of the lap, similar t< 

Tins operation should be repeated until the 
Mr • gi H .1 weld and the fillet has a ui 

uld i ali ulate 1 1 
i if fi - - rk he can do. 1 his work 

is simil 

eld i mly oni form 

Hit 14m to 150 amperi The 

.Mi and e> 

goo<l h 

2. Witl in the 

sin mill i\ 
i t| ljj" it 

\ f t e r 8 " l 1 o f t h e s e c i r i 

liould cle; tin -m tin -in 

.-mil v. around the tirst bead This 

similar to that oi welding iround the 
i tne i 't these circles sin iuld be cut 
tin.- ,' mined to see that it has been properly 

i -.-,-, nul bead is fused thoi 
plate and t' i the tirst bead This is an opei 
which must ' on ntghl\ mastei ed hi fore pri >c< - 

further. 

si consist* oi welding two pieces oi 
■ without beveling. If possible two 



pieces oi ' thickness boiler plate should be obtained 
for the exercise. Each edgi which is to be welded 
should be set in a horizontal position and a bead 
welded along the center of the plate. The second 
bead should then be welded in top of the first, remo\ 

lie oxide from the first before the second is ap 
plied. When both edge are thus prepared and put 

her the operator will have what amounts to 
beveled edges to weld together, but it will be neces- 
sar\ to weld from both sides in order to complete tin* 
job. One weld ol this nature should be made and cut 
I the operator maj examine it to sec that fusion 
has taken place mi the entire weld. 

is the one shown in the cut 

152 1 and consists ol w elding the caulking 

riveted joint and welding around the rivet 

head. The method of welding the caulking edge has 

plained. In welding around tin 

rivet head it is advisable to heat the rivet before weld- 

ead Witl the plate in a \ ertical 

the caulking edge i . draw an at c 

"ii the head of the first rivet, allowing the metal from 

tin- electrode to fall clear of the rivet head. Tins 

should be continued for about two ninutes or until 




Fig 152 



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TEN LESSONS IN ARC WELDING 



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in 




the rivet is thoroughly heated, then the fillet should be 

welded around the rivet. The operator should then 

skip two rivets and repeat the operation on the fourth 

The idea of skipping rivets is to keep the heat 




Fig is.; 

distributed so that contraction in the metal will nol 
set up shearing stresses in the rivets. By following 
the above practice a very tight joint will result when 



the metal of the rivets and plates cools. The result is 
similar to the result obtained by putting in a hot rivet 
and peening ii over. When such a rivet cools it con- 
tracts and pulls the plates tightly together. The op 
erator may turn the sample over and repeat the opera- 
tion on the nther side, perfecting it if possible. 

5. The exercise of welding an angle iron section is 
one which illustrates a type of job which is quite com- 
mon. The angle may he cut from a straight angle 
section ami the triangular shape cut out with a hack 
saw. The triangle is cut out so that the angle may- 
be bent at right angles. The tip of the triangular. 
however, must he cut square oft in order to allow a 
right angle to be bent without the edges coming en 
tirely together. The distance between the edges after 
the angle has been benl through 90 degrees should be 
equal to the thickness of the angle. The operator may 
then bridge cross the i w o edges from one side allowing 
as little metal to drop down between the edges as pos- 
sible. Then the angle should be turned over and the 
space between the edges completely filled b\ welding 
in one or more layers. 



LESSON fill 

Flue If eld in a 



This exercise deals with the welding oi lines into 
the due sheet of a boiler This work is encountered 
in fire tube hollers of all kinds. The operation re- 
quires ;i considerable amount of skill in handling the 
arc. A preparation of the flue sheet for welding in 
actual practice is usually what makes the job a su 
or failure. In practice the proper way of preparing a 
line sheet for welding is to put the hues in exactly as 
if they were not to he welded Idle boiler should 
then be fired at least once to allow the tubes to take 




ig. 154 



their permanent set, [Tie line sheet should then be 
sand blasted to dean the surfaces to he welded. If 
no s.md blast is available the pneumatic tool should 
he used to knock the oxide off the surfaces, after 
which the surfaces should he thoroughly brushed with 
a wire brush, then the welding may lie done. If the 
work is prepared in this manner and properly welded 
the results will he uniformly successful. 

Material required: Section of _." boiler plate with 
four 1" flues rolled in as shown in cut; s" electrode 
with 11.1(1 amperes should he used. 

1. Set the sample as shown in the photograph. Use 
head shield and hold the electrode holder in both hands 
as shown in the cut. The first flue at the top should 
be welded starting at the point shown in the cut and 
welding one-half wa\ around, moving from right to 
left. Then the other one-half wadded starting at the 
original point and moving downward to the left. The 
second flue should then be welded starting at the bot- 
tom and welding in two halves so that they meet at the 
top. The operator may then weld the other two tines 
by either of the two methods illustrated, depending 
upon which the operator likes the better. One of the 
lines should then be sawed in half to show the quality 
of the workmanship. 



Ih 



mini en wiiiiiiiiiiiiiuiiiiiii iiiiiiiiiiiimiimiiiiiiimiiiiiniiiiimiiinmiii 

TEN LESSONS IN ARC WELDING 



LESSON IX 

II elding Steel Castings with Carbon Arc 



Thi~ exercise illustrates the kind of work dune in a 
steel foundry and in certain n hops. The car- 

bon arc is used in the same manner as the tl.-.mc of an 
oxy-acetylene torch. From .->i » ■ to 600 amperes are 
required for carbon electrode work of this nature. 
The operator must use both I therefon 

shield is required The carbon electrode holder 
is held in the right hand and the welding i id if held 
in the left hand Carbon electrode welding is usually 
considered easier than metal electrode welding but 
there is considerable skill required to handle a . 
are successfully. 

Material required: One small steel casting(Fig 1 55 1 
carbon electrode holder, carbon electrode '/' in di- 
ameter sharpened to a point 

welding capacity in I iere unit is not available, 

two ISO-ampere units maj be connected i: 
welding rod 

1. For preliminat c practice tin 1 ' use 

the 300 unpen carbon are and cut into small pieces 
several pieces i i. For this \\ > irk the 

arc should he held approximately a quarter 
long. After the operator lias pi . . 
this wi Tk to be able ti i make a cl 
determined line, he should try welding 

d boiler plate si rap usii d the 

d to till in with. It will 







cult to control the arc ami lead it in any di 
direction. 

2. If . " carbon electrodes are available one should 
be sharpened and placed in the metal electrode holder 
and some cutting of " plate done using 150 amperes 

1'hi rator should be able to cut a straight, clean 

cut upon completing this exercise. 

3. Using the riveted sample which was used in 
ii VII the operator should use the 300 amperes 

carbon are to cut out a section of the upper plati 
tween two rivets. To perform this operation the plate 
should he set up in the same position in which it was 
welded s, , thai when the metal is melted by the carhop 
arc it can run down out of the cut. The sample should 
then later be welded flush, using the metal electrode 
process. After working with the carbon are and before 
working with the metallic arc on this job it will be 
xide i iff tlii' siirfaei ' 
lion arc forms a very thick coating 
ide. 

4. This exen with the correction of a flaw 
m the steel casting due to a sand spot. This .1 

■ii th" steel casting is caused by the crumbling of the 
ry to burn the sand spi i| ■ iul with 
are and till in new material from the weld- 
ere is no sand spot on the casting avail- 
able ii will be sufficient for the iperator to heat spol 
ximately r " in diatnetei to the molten state, then 
quickly break the are and strike the molten metal a 
alow with a ball-pein hammer. If tin- operator 
ei ition on a sand spot he would 
■ most of tin- sand by the heat of the 
harp Mow with the hammer throws the 
of the weld. The next 
the defect with new material 
The operation must he per- 
possible, otherwise the metal 
added ...- nil as the metal of the easting in the vicinity 
weld will he ruined hy the extreme heat. The 
Quid be ined ' short pieces of the weld- 

tould he melted and 
puddled in the proper place. In case the arc breaks 
during aid he started again on 

•h.t is net molten and the arc brought over into 

Liickly. If the arc is started bj 

touching the molten metal with the carbon elect! 

is very likely that the weld will be hard owing to the 

n from the electrode has gotten into 

the weld. \~ soon as the added material has been 

weld the arc must he broken. There 

is alw. dency on tin part of a beginner to play 

the are too long completed weld in an attempt 

ih finished appearance; thi= 

• in burning of the metal. In steel casting work 

a! hard spots two points must he observed: (1> 

isl I i done around the point at 

which the weld is 10 Si made with the arc so that it 

u ill not ' too fuddenly. (2> The carbon 

electrode must not lie brought in contact with the 

molten metal a- explained he: 

Tin- opei iuld he p si i 

by the operator until ! < can pi iduci a weld which is 
. to him. 



and si ag 
till in 
the weldinj 

■ II) as 



74 



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TEN LESSONS IN ARC WELDING 



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: iillllillllllllllll niiiiimiiiii 




LESSON X 

Cast Iron Welding 



The purpose of this exercise is to give the operator 
an idea of what can be accomplished with the electric 
arc on cast iron. The operator will frequently hear 
amazing statements as to what some particular operator 
has done along the line of welding cast iron but it is 
a fact that there are only a few commercial applica- 
tions of the process in the welding of cast iron. The 
difficulty in welding cast iron with the electric arc is 
not due to the fact that the metal cannot be properly 
fused, but is due to the fact that the sudden intense heat 
of the arc over ? local area results in the production of 
a hard weld and the introduction of contraction stresses 
which often result in cracking. Using the carbon 
welding process, cast iron welding rods may be fused 
into a cast iron piece. Using the metal electrode 
process and a soft iron or steel electrode, it is impos- 
sible to make a reliable weld between the added ma- 
terial and the cast iron. Using the metal electrode 
process certain work can be done by the introduction 
of steel studs in the cast iron pieces to be welded to- 
gether so that a certain amount of strength is obtained 
by the bond formed between the steel studs by the 
welded material. 

Material required: 300 amperes welding capacity. 
ft" cast iron welding rod. One small gray iron cast- 
ing ( Fig. 156). 

A small gray iron casting should be broken and the 
edges beveled, using the carbon arc for cutting. The 
pieces should then be placed in a carbon mold so that 
the molten iron when it is added will not run away 
from the joint. This is illustrated in Fig. 156. The 
carbon arc should be used to preheat the casting. 
It is not necessary to heat the piece to a red 
heat. The carbon arc and cast iron welding rod 
should then lie used to fuse tlie added material to the 
piece. As in Lesson IX, care should be exercised not to 
play the arc upon the weld any longer than is neces- 
sar\ to -ue complete fusion. In case the metal gets 



too hot and runs badly the arc must be broken and an 
interval of time allowed for it to cool slightly to 
eliminate the trouble. After the weld is completed the 
piece should be wrapped up securely in asbestos paper 
and allowed to cool slowly for 6 or 8 hours (larger 
pieces require from IS to 24 hours to cool). As an 
alternative to wrapping in asbestos paper, the piece 
may be covered in previously heated slacked lime. 
The idea of the lime is the same as the asbestos, to 
cool the casting slowly. If the work is properly pre- 
heated and welded rapidly and very slowly cooled the 
material in the weld will be as readily machineable as 
the balance of the piece. No flux of any kind is re- 
quired, although borax may be used. 




75 



LINCOLN MOTORS 



fhese motors are noted for the extreme rug- 
gedness and simplicity of their construction. 

They are insulated with a special compound 
which resists the destructive action of dust, dirt, 
chemical fumes, water, heal and cold. 

i in account of these features the\ arc particu- 
larly suitable for operating in foundries, steel 
mills, chemical plants, cotton mills, brick and tile 
plant-, ship-yards and other places where the 
working conditions are exceptional^ severe. 

Specifications 

Standard voltages II 11 to 2300 \< 'It-. 
I Uglier voltages can he obtained on special order. 

Phases- Two and three phase alternating cur- 
rent only. 

( yclcs 01 /' ' equal I M I, 10, , ; i I and ( ii • 

c\ cles per seci md. < >ther 

to 500 H. 1'. 

Temperature Ratings Lincoln Motors are 
guaranteed to operate at a temperature rise of 
not over 40 degrees ( . on continuous full load 
and 5? degrees C. on a 25'i overload for two 
hours. 

Ci uaraiitce I .mo >ln Motoi ai anteed 

tor a period of six months against all defect- of 
material or workmanship and we agree to replace 
free of charge f. o. b. Cleveland, parts which 
prove defective within that time, providing the 
detective part is returned to us in Cleveland. 
charm-- prepaid, and that inspection proves the 
claim. 

rices and n application. 




ROTOR 



STATOR 



; ■>-_• 







ithout damage to '1" winclinj 
i i of tin reliability of Un< 



LIBRARY OF CONGRESS 



016 091 716 7 



